Dodge - Ram 1500 4wd - Workshop Manual - 2002 - 2002 (2)

Factory Workshop Manual Make Dodge Model Ram 1500 4wd Engine and year Truck V8-5.9L VIN Z (2002) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Description and Operation Accessory Delay Relay: Description and Operation ACCESSORY RELAY The accessory relay works in conjunction with the FCM's power accessory delay features to control the operation of the radio, power windows, washer pump motors, wiper motor and power outlets. The accessory relay is turned ON by the FCM See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Modulethrough the relay's low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain ON or will time out and deactivate. The accessory relay remains ON in the RUN and ACCY ignition switch positions. In the UNLK and OFF positions, the relay will remain energized for 45 seconds and then deactivate. During this time-out period, if a driver or passenger door is opened, the relay will be deenergized immediately. While the ignition switch is in the START position, the relay will also drop out and then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren Alarm Module: Customer Interest Alarm System - Erroneous Horn Chirp/Alarm Siren NUMBER: 08-016-02 GROUP: Electrical DATE: September 2, 2002 SUBJECT: Horn Chirp and Erroneous Alarm OVERVIEW: This bulletin involves reprogramming the Forward Control Module (FCM) MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Two conditions have been identified which could be caused by electronic communication errors between the Forward Controller Module (FCM) and other electronic modules on the vehicle: The first condition can occur after a vehicle has been turned off and allowed to sit for more than a three minutes. A very brief horn chirp can sometimes be heard when a door is opened. When the engine is turned off the electronic modules continue to function, or stay awake for two to three minutes after shut down. After two to three minutes of inactivity the modules deactivate or go into a sleep mode. When a door is opened, the modules are activated or wake up. The brief horn chirp will occur at the time the modules wake up or when the door is opened. This can occur due to a communication error in the FCM. The second condition involves vehicles NOT equipped with Vehicle Theft Security System (VTSS) exhibiting an alarm with the horn sounding and lights flashing. This can also be caused by communication errors involving the FCM. Both of these condition have been corrected with software revisions in the FCM. Reprogramming the FCM with the latest software revision (version 5.4) will correct the conditions. DIAGNOSIS: If the vehicles exhibit either of the conditions described above, perform the Repair Procedure and reprogram the Front Controller Module (FCM). EQUIPMENT REQUIRED REPAIR PROCEDURE: 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the Front Controller Module (FCM) using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). The FCM software must be version 5.4 or later. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Customer Interest for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren > Page 16 FAILURE CODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren Alarm Module: All Technical Service Bulletins Alarm System - Erroneous Horn Chirp/Alarm Siren NUMBER: 08-016-02 GROUP: Electrical DATE: September 2, 2002 SUBJECT: Horn Chirp and Erroneous Alarm OVERVIEW: This bulletin involves reprogramming the Forward Control Module (FCM) MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Two conditions have been identified which could be caused by electronic communication errors between the Forward Controller Module (FCM) and other electronic modules on the vehicle: The first condition can occur after a vehicle has been turned off and allowed to sit for more than a three minutes. A very brief horn chirp can sometimes be heard when a door is opened. When the engine is turned off the electronic modules continue to function, or stay awake for two to three minutes after shut down. After two to three minutes of inactivity the modules deactivate or go into a sleep mode. When a door is opened, the modules are activated or wake up. The brief horn chirp will occur at the time the modules wake up or when the door is opened. This can occur due to a communication error in the FCM. The second condition involves vehicles NOT equipped with Vehicle Theft Security System (VTSS) exhibiting an alarm with the horn sounding and lights flashing. This can also be caused by communication errors involving the FCM. Both of these condition have been corrected with software revisions in the FCM. Reprogramming the FCM with the latest software revision (version 5.4) will correct the conditions. DIAGNOSIS: If the vehicles exhibit either of the conditions described above, perform the Repair Procedure and reprogram the Front Controller Module (FCM). EQUIPMENT REQUIRED REPAIR PROCEDURE: 1. Connect a Battery Charger and set as close to 14 volts charge as possible. 2. Flash reprogram the Front Controller Module (FCM) using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). The FCM software must be version 5.4 or later. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alarm Module: > 08-016-02 > Sep > 02 > Alarm System - Erroneous Horn Chirp/Alarm Siren > Page 22 FAILURE CODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 23 Sentry Key Immobilizer Module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 24 Alarm Module: Description and Operation SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency (RF) transceiver and a central processing unit, which includes the Sentry Key Immobilizer System (SKIS) program logic. The SKIS programming enables the SKIM to program and retain in memory the codes of at least two, but no more than eight electronically coded Sentry Key transponders. The SKIS programming also enables the SKIM to communicate over the Programmable Communication Interface (PCI) bus network with the Powertrain Control Module (PCM), and/or the DRB III scan tool. The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ring that is integral to the SKIM housing. When the SKIM is properly installed on the steering column, the antenna ring is oriented around the ignition lock cylinder housing. This antenna ring must be located within eight millimeters (0.31 inches) of the Sentry Key in order to ensure proper RF communication between the SKIM and the Sentry Key transponder. For added system security each SKIM is programmed with a unique "Secret Key" code and a security code. The SKIM keeps the "Secret Key" code in memory The SKIM also sends the "Secret Key" code to each of the programmed Sentry Key transponders. The security code is used by the assembly plant to access the SKIS for initialization, or by the dealer technician to access the system for service. The SKIM also stores in its memory the Vehicle Identification Number (VIN), which it learns through a PCI bus message from the PCM during initialization. The SKIM and the PCM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized SKIS disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM. However, the use of this strategy also means that replacement of either the SKIM or the PCM units will require a system initialization procedure to restore system operation. When the ignition switch is turned to the ON or START positions, the SKIM transmits an RF signal to excite the Sentry Key transponder. The SKIM then listens for a return RF signal from the transponder of the Sentry Key that is inserted in the ignition lock cylinder. If the SKIM receives an RF signal with valid "Secret Key" and transponder identification codes, the SKIM sends a "valid key" message to the PCM over the PCI bus. If the SKIM receives an invalid RF signal or no response, it sends "invalid key" messages to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. The SKIM also sends messages to the Instrument Cluster which controls the VTSS indicator LED. The SKIM sends messages to the Instrument Cluster to turn the LED ON for about three seconds when the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends bus messages to keep the LED OFF for a duration of about one second. Then the SKIM sends messages to turn the LED ON or OFF based upon the results of the SKIS self-tests. If the VTSS indicator LED comes ON and stays ON after the bulb test, it indicates that the SKIM has detected a system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the ignition switch is turned to the ON position, it sends messages to flash the VTSS indicator LED. The SKIM can also send messages to flash the LED as an indication to the customer that the SKIS has been placed in it's "Customer Learn" programming mode. See Sentry Key Immobilizer System Transponder Programming in this section for more information on the "Customer Learn" programming mode. For diagnosis or initialization of the SKIM and the PCM, a DRB III scan tool and the proper Powertrain Diagnostic Procedures manual are required. The SKIM cannot be repaired and, if faulty or damaged, the unit must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Page 25 Alarm Module: Service and Repair SENTRY KEY IMMOBILIZER MODULE REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column upper and lower shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the steering column wire harness connector from the Sentry Key Immobilizer Module (SKIM). Fig. 6 Sentry Key Immobilizer Module (SKIM) 4. Remove the screw securing the SKIM module to the steering column. 5. Release the SKIM antenna ring retaining clips from around the ignition switch lock cylinder housing and remove the SKIM. INSTALLATION NOTE: If the SKIM is replaced with a new unit, a DRB III scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE). 1. Slide the SKIM antenna ring around the ignition switch lock cylinder housing and clip in place. 2. Install the retaining screw. 3. Connect the steering column wire harness connector to the Sentry Key Immobilizer Module (SKIM). 4. Install the steering column upper and lower shrouds. Refer to Steering, Column, Shroud, Installation. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 29 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned OFF, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to pulse for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Refer to the owner's manual for more information on the features, use and operation of the RKE system. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a DRB III scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, (Refer to POWER LOCKS/KEYLESS ENTRY TRANSMITTER - STANDARD PROCEDURE). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 30 Keyless Entry Module: Testing and Inspection Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Refer to the proper Body Diagnostic Procedures Manual for testing the Remote Keyless Entry system using a DRB III scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 31 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster (Refer to INSTRUMENT CLUSTER - REMOVAL). Fig. 5 Remote Keyless Entry Module 3. Remove remote keyless entry module from instrument cluster. INSTALLATION 1. Install remote keyless entry module to instrument cluster. 2. Install instrument cluster (Refer to INSTRUMENT CLUSTER - INSTALLATION) 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation RELAY PACK DESCRIPTION Relay Pack Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. OPERATION In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay Winch Relay: Service and Repair Winch Relay RELAY REMOVAL 1. Remove the relay pack (1). 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 37 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 38 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). 3. Tighten the nuts to 3 N.m (25 in.lbs.) 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 N.m (85 in.lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 39 6. Install the relay pack (1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 40 Winch Relay: Service and Repair Winch Relay Pack RELAY PACK REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 41 3. Remove the nut and disconnect the red battery positive cable (1). NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. INSTALLATION NOTE: Relay #4 shown, all others similar. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 42 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 N.m (25 in.lbs.). 3. Install the red battery positive cable (1) and install the switch wire. 4. Install the nut and tighten to 10 N.m (85 in.lbs.). 5. Install the relay pack cover (1) and install the three screws (2). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Winch Relay > Page 43 6. Install the winch assembly (2). 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams Door Module: Diagrams Driver Door Module - C1 Driver Door Module - C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 48 Door Module: Description and Operation DRIVER DOOR MODULE A Driver Door Module (DDM) is used on all models equipped with power locks, power windows, and power mirrors. The DDM houses the following switches: Power Lock Switch - The DDM includes a two-way, momentary, resistor multiplexed switch to control the power lock system. Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way latching, push-button switch in the DDM allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches in the DDM. - Power Window Switches - The DDM houses a two-way momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window. The DDM also incorporates several green Light- Emitting Diodes (LED s) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility in dark ambient lighting conditions. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must be replaced. The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the ON or Accessory positions. Power Window Switches The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Each two-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The DDM switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The DDM power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery current through the power window circuit breaker in the IPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 49 Door Module: Testing and Inspection DRIVER DOOR MODULE The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Integrated Power Module (IPM). If all of the LEDs are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Fig.2 Driver Door Module Connector C1 Receptacle Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 50 Fig. 3 Driver Door Module Connector C2 Receptacle (Part 1 Of 2) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 51 Fig. 3 Driver Door Module Connector C2 Receptacle (Part 2 Of 2) 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position and/or. If not OK, replace the faulty DDM as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Page 52 Door Module: Service and Repair DRIVER DOOR MODULE REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 4 Driver Door Module 2. Using a trim stick, gently pry the driver door module from the door panel. 3. Disconnect the electrical harness connectors from the driver door module. INSTALLATION 1. Connect electrical harness connectors to the driver door module. 2. Position driver door module to door trim panel and press into place. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Diagrams Heated Mirror Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Diagrams > Page 56 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Diagrams > Page 57 Heated Mirror Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Diagrams > Page 58 Heated Mirror Relay: Description and Operation ELECTRICALLY HEATED SYSTEMS HEATED MIRROR RELAY A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTC's. A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Information Bus Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Diagrams > Page 59 Heated Mirror Relay: Testing and Inspection DIAGNOSIS AND TESTING - HEATED MIRROR SYSTEM If only one of the outside mirror heating grids is inoperative, perform continuity checks on the circuits and heater grid for that mirror only. If both outside mirror heating grids are inoperative, proceed with the heated mirror system diagnosis as follows. (Refer to Appropriate Wiring Information)See: Diagrams WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The operation of the heated mirror system can be confirmed in one of the following manners: 1. Turn the ignition switch to the On position. While monitoring the instillment panel voltmeter, momentarily depress and release the heated mirror switch. When the heated mirror system is turned on, a distinct voltmeter needle deflection should be noted 2. Turn the ignition switch to the On position. Momentarily depress and release the heated mirror switch to turn the heated mirror system On. The heated mirror operation can be checked by feeling the outside rear view mirror glass. A distinct difference in temperature between the unheated and heated mirror glass can be detected within three to four minutes of system operation. The above checks will confirm system operation. Illumination of the heated mirror system indicator lamp means that there is electrical current available at the heated mirror relay, but does not confirm that the electrical current is reaching the outside mirror heating grids. If the heated mirror system does not operate, the problem should be isolated in the following manner: 1. Confirm that the ignition switch is in the On position. 2. Check the fuses in the Power Distribution Center (PDC) and in the Junction Block (JB). The fuses must be tight in their receptacles and all electrical connections must be secure. See: Power and Ground Distribution When the above steps have been completed and both outside mirror heating grids are still inoperative, one or more of the following is faulty: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 63 Keyless Entry Module: Description and Operation REMOTE KEYLESS ENTRY MODULE When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned OFF, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned ON and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to pulse for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Refer to the owner's manual for more information on the features, use and operation of the RKE system. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a DRB III scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, (Refer to POWER LOCKS/KEYLESS ENTRY TRANSMITTER - STANDARD PROCEDURE). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 64 Keyless Entry Module: Testing and Inspection Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. Refer to the proper Body Diagnostic Procedures Manual for testing the Remote Keyless Entry system using a DRB III scan tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 65 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster (Refer to INSTRUMENT CLUSTER - REMOVAL). Fig. 5 Remote Keyless Entry Module 3. Remove remote keyless entry module from instrument cluster. INSTALLATION 1. Install remote keyless entry module to instrument cluster. 2. Install instrument cluster (Refer to INSTRUMENT CLUSTER - INSTALLATION) 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Seat Heater Control Module: Locations The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 69 Seat Heater Interface Module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 70 Seat Heater Control Module: Description and Operation Fig. 2 Heated Seat Module HEATED SEAT MODULE The heated seat module is also known as the Seat Heat Interface Module. The heated seat module is located under the drivers front seat cushion, where it is secured to a mounting bracket. The heated seat module has a single connector receptacle that allows the module to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat module is an electronic microprocessor controlled device designed and programmed to use inputs from the battery, the two heated seat switches and the two heated seat sensors to operate and control the heated seat elements in both front seats and the two heated seat indicator lamp Light- Emitting Diodes (LEDs) in each heated seat switch. The heated seat module is also programmed to perform self-diagnosis of certain heated seat system functions and provide feedback of that diagnosis through the heated seat switch indicator lamps. The heated seat module cannot be repaired. If the heated seat module is damaged or faulty the entire module must be replaced. The heated seat module operates on fused battery current received from the integrated power module. Inputs to the module include a resistor multiplexed heated seat switch request circuit for each of the two heated seat switches and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and sensors, and controls the ground for the heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat system is operating. At the same time, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is about 36 °C (96.8 °F), and the High heat set point is about 42 °C (107.6 °F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. If the heated seat module detects a heated seat sensor value input that is out of range or a shorted or open heated seat element circuit, it will notify the vehicle operator or the repair technician of this condition by flashing the High and/or Low indicator lamps in the affected heated seat switch. Refer to Diagnosis and Testing Heated Seat System in Heated Systems for flashing LED diagnosis and testing procedures. Refer to Diagnosis and Testing Heated Seat Module in this section for heated seat module diagnosis and testing procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 71 Seat Heater Control Module: Testing and Inspection If a heated seat fails to heat and one or both of the indicator lamps on a heated seat switch flash, refer to Diagnosis and Testing Heated Seat System in Heated Seats for the location of flashing LED heated seat system diagnosis and testing procedures. If a heated seat heats but one or both indicator lamps ON the heated seat switch fail to operate, test the heated seat switch. Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for heated seat switch diagnosis and testing procedures. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element (Refer to HEATED SEATS/HEATED SEAT ELEMENT DIAGNOSIS AND TESTING). 2. Check the heated seat sensor (Refer to HEATED SEATS/HEATED SEAT SENSOR - DIAGNOSIS AND TESTING). 3. Check the heated seat switch (Refer to HEATED SEATS/DRIVER HEATED SEAT SWITCH - DIAGNOSIS AND TESTING). NOTE: Refer to Wiring for the location of complete heated seat system wiring diagrams and connector pin-out information. 4. Using a voltmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to Step 5, if Not, Repair the open or shorted voltage supply circuit as required. 5. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module with a known good unit and retest system, if Not OK, Repair the open or shorted ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 72 Seat Heater Control Module: Service and Repair REMOVAL 1. Position the driver seat to the full rearward and inclined position. 2. Working under the driver front seat, remove the two heated seat module retaining screws. Due to the fact that the retaining screws are installed with the seat cushion pan removed, a small right angle screwdriver will be required to access and remove the screws. 3. Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module. Depress the connector retaining tab and pull straight apart. 4. Remove the heated seat module from under the front seat. INSTALLATION 1. Position the heated seat module under the front seat. 2. Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module. 3. Working under the driver front seat install the heated seat module retaining screws 4. Re-position the driver seat. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Controller Mounting Screws 53 inch lbs. RWAL Module Mounting Bolts 11 ft. lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 77 Electronic Brake Control Module: Locations EBC 125 (RWAL) EBC 325 (ABS) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions Electronic Brake Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 Electronic Brake Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Electronic Brake Control Module: Connector Views Controller Antilock Brake C1 Controller Antilock Brake C2 (ABS) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 Electronic Brake Control Module: Electrical Diagrams Controller Antilock Brake - EBC 125 (RWAL) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 Controller Antilock Brake - EBC 325 (ABS) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 100 Electronic Brake Control Module: Description and Operation Fig. 1 Hydraulic Control Unit CONTROLLER ANTILOCK BRAKE The Controller Antilock Brake (CAB) is mounted to the Hydraulic Control Unit (HCU) and operates the ABS system. The CAB voltage source is through the ignition switch in the RUN position. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 101 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the CAB harness connector release and remove connector. 3. Remove the CAB mounting bolts. 4. Remove the pump connector from the CAB. 5. Remove the CAB from the HCU. INSTALLATION 1. Install CAB to the HCU. 2. Install the pump connector to the CAB. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the CAB and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service Precautions Blower Motor Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service Precautions > Page 106 Blower Motor Relay: Description and Operation The blower motor relay is a International Standards Organization (ISO) -type relay The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. The blower motor relay is installed in a wire harness connector that is secured to the passenger side outboard end of the HVAC housing in the passenger compartment, next to the HVAC wire harness connector. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service Precautions > Page 107 Blower Motor Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 15 Blower Motor Relay RELAY TEST The blower motor relay is located in the PDC which is located under the hood.. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 60.7 to 80.3 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST For circuit descriptions and diagrams. 1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the connector cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the connector cavity for terminal 87 and the blower motor at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the ON position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the connector cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnet coil. There should be continuity between the connector cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service Precautions > Page 108 Blower Motor Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the blower motor relay from the PDC located under the hood. 3. Remove the blower motor relay. INSTALLATION 1. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Connect the battery negative cable. 3. Test the relay operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 112 Compressor Clutch Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 113 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 114 A/C Compressor Clutch Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 115 Compressor Clutch Relay: Description and Operation The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the A/C Heater mode control switch, the A/C low pressure switch, and the A/C high pressure switch. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 116 Compressor Clutch Relay: Testing and Inspection Fig. 10 Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 67.5 to 82.5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST For circuit descriptions and diagrams. 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 117 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. INSTALLATION 1. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 2. Install the PDC cover. 3. Connect the battery negative cable. 4. Test the relay operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 121 Condenser Fan Motor Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 122 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 123 Condenser Fan Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination Instrument Panel Control Module: Customer Interest Instruments - Erroneous Indicator lamp Illumination NUMBER: 08-004-03 GROUP: Electrical DATE: March 14, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2129 OR HIGHER, AVAILABLE MARCH 31, 2003 SUBJECT: Flash: Electro Mechanical Instrument Cluster - erroneous indicator lamps OVERVIEW: This bulletin involves selectively erasing and reprogramming the Electro Mechanical Instrument Cluster (MIC) with new software. MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Three conditions have been identified which may be caused by communication errors between the Electro Mechanical Instrument Cluster (MIC) and other electronic modules on the vehicle. 1. An intermittent false "Check Gauges" on diesel engine equipped vehicles. 2. An intermittent false chime and "Low Wash" indicator. A valid "Low Wash" indication will occur for at least a 30 second interval. With this false condition, the chime will occur followed by the "Low Wash" indicator which will last for a half second or less. 3. A "Trans Temp" Indicator on a manual transmissions equipped vehicle. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is present, perform the Repair Procedure. EQUIPMENT REQUIRED REPAIR PROCEDURE: NOTE: WHEN FLASH REPROGRAMMING THE MIC, IT IS IMPORTANT THAT NO ELECTRONIC COMMUNICATION OCCURS BETWEEN THE MIC AND OTHER MODULES IN THE VEHICLE. ADDITIONAL STEPS HAVE BEEN ADDED TO THE FLASH PROCEDURE TO PREVENT THIS FROM HAPPENING. 1. Inspect the radio face plate. The radio sales code is printed on the face of the radio. If the vehicle is equipped with an "RAZ" radio, it must be removed from the instrument panel and disconnected to eliminate the possibility of any electronic communication between the radio and the instrument cluster during the flash procedure. 2. Remove the ABS module fuse (# 35) from the fuse panel. This will prevent any communications between the ABS module and the instrument cluster during the flash procedure. 3. Connect a battery charger and set as close to 14 volts charge as possible. 4. Flash the MIC using the TechConnect/MDS2 (Mopar Diagnostic System) and DRBIII(R). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination > Page 133 NOTE: DUE TO THE REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (PCM, TCM, BCM, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination Instrument Panel Control Module: All Technical Service Bulletins Instruments - Erroneous Indicator lamp Illumination NUMBER: 08-004-03 GROUP: Electrical DATE: March 14, 2003 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE TechCONNECT/MDS2 MUST BE OPERATING WITH CIS CD2129 OR HIGHER, AVAILABLE MARCH 31, 2003 SUBJECT: Flash: Electro Mechanical Instrument Cluster - erroneous indicator lamps OVERVIEW: This bulletin involves selectively erasing and reprogramming the Electro Mechanical Instrument Cluster (MIC) with new software. MODELS: 2002 - 2003 (DR) Ram Truck SYMPTOM/CONDITION: Three conditions have been identified which may be caused by communication errors between the Electro Mechanical Instrument Cluster (MIC) and other electronic modules on the vehicle. 1. An intermittent false "Check Gauges" on diesel engine equipped vehicles. 2. An intermittent false chime and "Low Wash" indicator. A valid "Low Wash" indication will occur for at least a 30 second interval. With this false condition, the chime will occur followed by the "Low Wash" indicator which will last for a half second or less. 3. A "Trans Temp" Indicator on a manual transmissions equipped vehicle. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is present, perform the Repair Procedure. EQUIPMENT REQUIRED REPAIR PROCEDURE: NOTE: WHEN FLASH REPROGRAMMING THE MIC, IT IS IMPORTANT THAT NO ELECTRONIC COMMUNICATION OCCURS BETWEEN THE MIC AND OTHER MODULES IN THE VEHICLE. ADDITIONAL STEPS HAVE BEEN ADDED TO THE FLASH PROCEDURE TO PREVENT THIS FROM HAPPENING. 1. Inspect the radio face plate. The radio sales code is printed on the face of the radio. If the vehicle is equipped with an "RAZ" radio, it must be removed from the instrument panel and disconnected to eliminate the possibility of any electronic communication between the radio and the instrument cluster during the flash procedure. 2. Remove the ABS module fuse (# 35) from the fuse panel. This will prevent any communications between the ABS module and the instrument cluster during the flash procedure. 3. Connect a battery charger and set as close to 14 volts charge as possible. 4. Flash the MIC using the TechConnect/MDS2 (Mopar Diagnostic System) and DRBIII(R). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 08-004-03 > Mar > 03 > Instruments - Erroneous Indicator lamp Illumination > Page 139 NOTE: DUE TO THE REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (PCM, TCM, BCM, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Integrated Power Module (Front View) The front fog lamp relay is located in the Power Distribution Center (PDC) in the engine compartment of the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 144 Fog/Driving Lamp Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 145 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 146 Fog Lamp Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 147 Fog/Driving Lamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 148 Fog/Driving Lamp Relay: Description and Operation FOG LAMP RELAY If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn ON the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. The FCM "learns" that the vehicle is equipped with fog lamps by reading the instrument cluster PCI bus message. Fig.11 ISO Micro Relay The front fog lamp relay is located in the Power Distribution Center (PDC) See: Relays and Modules - Power and Ground Distribution/Relay Box Applications and ID in the engine compartment of the vehicle. The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The front fog lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front fog lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front fog lamp relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the front fog lamp relay include: Common Feed Terminal - The common feed terminal (30) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a front fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery voltage at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the front fog lamps through a front fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. Normally Closed Terminal - The normally closed terminal (87A) is not connected in this application. The front fog lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 149 Fog/Driving Lamp Relay: Testing and Inspection FRONT FOG LAMP RELAY Fig.11 ISO Micro Relay The front fog lamp relay is located in the Power Distribution Center in the engine compartment. See: Relays and Modules - Power and Ground Distribution/Relay Box Applications and ID. Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the front fog lamp relay from the PDC. (Refer to LAMPS/LIGHTING EXTERIOR/FRONT FOG LAMP RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 150 Fog/Driving Lamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cover for the Power Distribution Center (PDC). 3. Remove the front fog lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the front fog lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the front fog lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the front fog lamp relay until the terminals are fully seated in the PDC. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations 8W-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams Horn Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 157 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 158 Horn Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 159 Horn Relay: Description and Operation HORN RELAY The Horn Relay, which is internal to the Integrated Power Module (IPM), is controlled by the Front Control Module (FCM) through PCI bus messages from the instrument cluster. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Information Bus See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). Under normal operating conditions, if the horn is activated for more than 30 seconds, the FCM will automatically deactivate the horn to prevent damage. The FCM will reactivate control of the relay after a 25 second cool-down period. The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTC's. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Integrated Power Module (Front View) The park lamp relay is located in the Power Distribution Center (PDC) of the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 163 Parking Lamp Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 164 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 165 Park Lamp Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 166 Parking Lamp Relay: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 167 Parking Lamp Relay: Description and Operation PARK LAMP RELAY The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Fig.11 ISO Micro Relay The park lamp relay is located in the Power Distribution Center (PDC) of the vehicle. The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The park lamp relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the park lamps. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The park lamp relay terminals are connected to the vehicle electrical system through a connector in the Junction Block (JB). The inputs and outputs of the headlamp low beam relay include: Common Feed Terminal - The common feed terminal (30) is connected to the park lamps through the park lamp relay output circuit and provides ground to the park lamps when the relay is de-energized, and battery current to the park lamps whenever the relay is energized. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the PDC through a fused B(+) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The park lamp relay can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 168 Parking Lamp Relay: Testing and Inspection Fig.11 ISO Micro Relay The park lamp relay is located in the Power Distribution Center (PDC). Refer to the appropriate wiring information. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Remove the park lamp relay from the PDC. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 169 Parking Lamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the park lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the park lamp relay to the proper receptacle in the Power Distribution Center (PDC). 2. Align the park lamp relay terminals with the terminal cavities in the PDC. 3. Press firmly and evenly on the top of the park lamp relay until the terminals are fully seated in the PDC. 4. Install the PDC cover. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams Trailer Lighting Relay: Diagrams Trailer Tow Left Turn Relay Trailer Tow Right Turn Relay Electric Brake Provision Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Description and Operation Micro ISO Relay: Description and Operation Fig. 9 DR ISO Micro Relay MICRO RELAY A micro-relay is a conventional International Standards Organization (ISO) micro relay (Fig. 9). Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. Relays cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. A micro-relay is an electromechanical switch that uses a low current input from one source to control a high current output to another device. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Description and Operation > Page 177 Micro ISO Relay: Testing and Inspection 1. Remove the relay from its mounting location. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 67.5 - 82.5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III scan tool to perform further testing. Refer to the appropriate diagnostic information. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Description and Operation > Page 178 Micro ISO Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process. INSTALLATION 1. Align the micro-relay terminals with the terminal cavities in the receptacle. 2. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle. 3. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation Power Distribution Module: Description and Operation FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board-based module with an on-board micro-processor. The Front Control Module interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus (J1850). In order to obtain conclusive testing the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the front control module must be checked. All PCI (J1850) communication faults must be resolved prior to further diagnosing any front control module related issues. The Front Control Module was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III. The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III scan tool and the proper Body Diagnostic Procedures manual. Before any testing of the front control module is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. The Front Control Module is a micro-controller based module located in the left front corner of the engine compartment. On this model, the Integrated Power Module must be positioned aside in order to access the front control module. The Front Control Module mates to the Power Distribution Center to form the Integrated Power Module (IPM). The Integrated Power Module connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The Front Control Module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit (J1850). For information on the Integrated Power Module, refer to the Power Distribution Center. As messages are sent over the PCI bus circuit, the Front Control Module reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the Front Control Module: Airbag (Restraints) System - Headlamp Power with Voltage Regulation - Electronic Transmission Control Module Power - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Brake Shift Interlock System - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Blower Motor Relay Actuation - Accessory Relay Actuation - Horn Relay Actuation - Electronic Back Light (EBL) Rear Defogger - Horn Relay Actuation - Name Brand Speaker (NBS) Relay Actuation The following inputs are Received/Monitored by the Front Control Module: B+ Connection Detection - Power Ground - Battery IOD - Ambient Temperature Sensing - Park Lamp Outage - Ignition Switch Start Only - Ignition Switch Run and Start Only - Washer Fluid Level Switch - Windshield Wiper Park Switch - Brake Fluid Level Switch - PCI Bus Circuit - Brake Lamp Switch - Flash Reprogramming Voltage - Horn Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation Fig. 8 ISO Relay A relay (Fig. 8) is an electromechanical device that switches fused battery current to a electrical component when the ignition switch is turned to the Accessory or Run positions, or when controlled by a electronic module. The relays are located in the integrated power module. The relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. A relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation > Page 185 Power Distribution Relay: Testing and Inspection The relays are located in the integrated power module. For complete circuit diagrams, refer to Wiring Diagrams. 1. Remove the relay from its mounting location. 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 60.7 - 80.3 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform the Relay Circuit Test that follows. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) of the integrated power module is connected to battery voltage and should be hot at all times. Check for battery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay. If OK, go to Step 2. If not OK, repair the fused B(+) circuit to the integrated power module fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the fused B(+) fuse in the integrated power module that feeds the accessory when the relay is energized by the ignition switch. There should be continuity between the integrated power module cavity for relay terminal 87 and the fused B(+) fuse in the integrated power module at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required. 4. The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the relay when the ignition switch is in the Accessory or Run positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the integrated power module receptacle for the relay If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required. 5. The coil battery terminal (86) is connected to the electromagnet in the relay. The integrated power module cavity for this terminal should have continuity to ground at all times. If not OK, repair the open ground circuit to ground as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation > Page 186 Power Distribution Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process. INSTALLATION 1. Position the relay to the proper receptacle. 2. Align the relay terminals with the terminal cavities in the receptacle. 3. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle. 4. Connect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 190 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 191 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 192 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 193 Relay Box: Application and ID Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 194 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 195 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 196 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions Body Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjuction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTC's), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTC's) to the technician through the DRB III via the PCI bus. Some circuits are tested continously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 ° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Passenger Airbag ON-OFF Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 204 The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition ON. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Side Impact Airbag Control Module (SIACM) Supplemental driver and front passenger curtain airbags provide side impact protection for the front and rear seat occupants. Each curtain airbag has its own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just below the seat belt retractor. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. The results of the system test are transmitted on the PCI Bus to the ACM once each second. If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Curtain Airbags The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 ° C (200 ° F). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 205 REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Special Tools Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or mis-alignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 206 Body Control Module: Description and Operation Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRB III. When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Remote Radio Controls These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRB III. The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 207 Body Control Module: Description and Operation Body Control System SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The Body System on the 2002 DR Ram Truck consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 208 Body Control Module: Description and Operation Communication COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. One splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on this vehicle: Front Control Module - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - A/C Heater Control Module - Powertrain Control Module - Radio - Amplifier (if equipped) - Transmission Control Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 209 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 210 vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS (+/-) SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 211 Body Control Module: Description and Operation Airbag System AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjuction with the seat belt system. The Airbag Control Module (ACM) is an electronic module that monitors the airbag system for proper operation, stores diagnostic trouble code (DTC's), controls the airbag warning lamp and contains the sensor and actuator that is responsible for airbag deployment. There are no external impact sensors. The ACM is mounted on a special bracket that is fastened to the floor of the truck at the bottom of the instrument panel. It is located forward of the console. The ACM provides diagnostic information (DTC's) to the technician through the DRB III via the PCI bus. Some circuits are tested continously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Electro/Mechanical Instrument Cluster (EMIC) from the ACM via the PCI bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the "run" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp ON for 6-8 seconds. If the lamp remains OFF, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains ON, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes ON and stays ON for a period longer than 6-8 seconds, then goes OFF, there is usually an intermittent problem in the system. WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Driver Airbag The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consist of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. Passenger Airbag When supplied with the proper electrical signal the passenger airbag inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 ° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 212 Passenger Airbag ON-OFF Switch The Passenger Airbag ON-OFF Switch allows the customer to turn the passenger airbag function ON or OFF. The OFF indicator will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. To operate, insert the ignition key into the switch keyhole, push key in to release the internal plunger, and rotate to the desired switch position. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. The ignition key is the only key or object that should ever be inserted into the switch. NOTE: Do not turn the ON-OFF switch with the ignition ON. The ACM continuously monitors the resistance of the Passenger Airbag ON-OFF Switch circuits to identify the switch position and provide circuit diagnostics. The ON-OFF switch ON position resistance is 175 to 190 ohms and the OFF position resistance is 820 to 870 ohms. If the ON-OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. WARNING: IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Seat Belt Tensioner Front seat belt systems incorporate Tensioner Modules (SBT). At the onset of an impact event each tensioner uses a pyrotechnic device, which is triggered simultaneously with the airbags, to rapidly retract the seat belts. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. The ACM module monitors the Seat Belt Tensioners circuit resistance and reports active and stored DTC's if any problem is found. Side Impact Airbag Control Module (SIACM) Supplemental driver and front passenger curtain airbags provide side impact protection for the front and rear seat occupants. Each curtain airbag has its own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just below the seat belt retractor. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. The results of the system test are transmitted on the PCI Bus to the ACM once each second. If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Curtain Airbags The Left and Right curtain airbags are located in the outboard edge of the roof under the headliner, just above the door openings. When supplied with the proper electrical signal the inflator can discharge the compress gas directly into the curtain airbag. Upon deployment, the curtain will tear open the headliner allowing the curtain airbag to fully deploy between the headliner and seat. The curtain airbag cannot be repaired and must be replaced if deployed or in any way damaged. WARNING: THE CURTAIN AIRBAG CONTAINS AN INERT GAS PRESSURIZED TO 17236.89 Kpa (2500 PSI). DO NOT ATTEMPT TO Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 213 DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93 ° C (200 ° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. Special Tools Some airbag diagnostic test use special tools, airbag load tools, 8310 and 8443 for testing squib circuits. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or mis-alignment. Substitute the airbag load tool in place of an Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all component in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB III. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected and stored after one minute of occurrence or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes Airbag codes are automatically stored in the ACM's memory after one minute of occurrence or when the ignition is turned OFF. The exception is the "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "ON" wiggle the wire harness and connectors, rotate the steering wheel from Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 214 stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System AUDIO SYSTEM The factory installed radio receiver communicates on the Programmable Communication Interface (PCI) data bus network. The PCI Bus inputs into the radio are used for VF dimming and remote steering wheel controls. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRB III. When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or "output" error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term "output" refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. Remote Radio Controls These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Instrument Cluster (MIC) and can be read with the DRB III. The switches are a multiplexed signal to the MIC. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the MIC and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the MIC. The ground must be complete so that the switches can cause the voltage drop for the MIC to see. The circuit passes through the clockspring so continuity through this devise must be verified. Amplifier (Premium System) The Premium Audio Amplifier uses a microprocessor for audio digital signal processing (DSP) and system diagnostics. DSP provides a more accurate and consistent match of the audio system equalization to the vehicle interior. The O2 DR Ram amplifier has six channels for superior sound quality. The amplifier reads the VIN from the PCI bus and sets itself to match the vehicle. The amplifier will send four beeps to the vehicle speakers at ignition ON, if it does not read the VIN correctly. A replacement amplifier may beep at the first power up, but if these beeps are heard after the first ignition ON, the DRB III should be used to verify the amplifier is connected to the PCI bus and that the VIN on the PCI bus is correct. The amplifier, wiring to the speakers and the speakers work independently from the radio. The amplifier's microprocessor supports several diagnostic functions. Tests can be run from the DRB III that will help in diagnosing audio system problems. The DRB III can display fault messages when an input or output problem to the amplifier is detected. The amplifier can detect wiring shorts and suggest which wires are likely to be shorted. The amplifier can send test signals that can be used to verify that the amplifier, speakers, and wiring to the speakers are operating properly. The amplifier can also be used to test if the radio is sending audio signals to it. The DRB III can be used to verify the amplifier equalization setting matches the vehicle, in case there is a sound quality complaint. Using the DRB III audio system diagnostics can determine the nature of the problem. Diagnostic test the Amplifier can perform through the DRB III: Continuous Tone Test - This test will send a continuous tone to each speaker and will verify the integrity of an individual channel. PCI Amplifier Test - This test will detect a PCI bus or checksum failure. Input Test - This test will detect the activity on the amplifiers input channels from the radio. Speaker Output Test - This test will detect the activity on the amplifiers output channels to the speakers. Body Control System SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The Body System on the 2002 DR Ram Truck consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages "addressed" to it through binary coding process. This method of data transmission significantly reduces the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 215 complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus. Communication COMMUNICATION The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. One splice called the Diagnostic Junction Port, serves as the "Hub" of the bus. The Diagnostic Junction Port provides an access point to isolate most of the modules on the bus in order to assist in diagnosing the circuit. The following modules are used on this vehicle: Front Control Module - Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Airbag Control Module - Controller Antilock Brake - A/C Heater Control Module - Powertrain Control Module - Radio - Amplifier (if equipped) - Transmission Control Module - Transfer Case Control Module (if equipped) - Sentry Key Immobilizer Module - Compass Mini-Trip Computer (if equipped) - Electro/Mechanical Instrument Cluster Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 216 The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRB III lab scope. The 12v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open circuit at either the Diagnostic Junction Port or the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: All gauges on the EMIC stay at zero - All telltales on EMIC illuminate - EMIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRB III. Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 217 vehicle is equipped with and then attempt to get a response from the modules with the DRB III. If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRB III may display "BUS (+/-) SIGNAL OPEN" or "NO RESPONSE" to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRB III and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. Self-Check Diagnostics SELF-CHECK DIAGNOSTICS The CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. CMTC/EVIC diagnostics may be performed using a DRB III or by using the following procedure: 1. With the ignition switch in the OFF position, depress and hold the RESET and the C/T buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the CMTC/EVIC will display one of the following messages: PASS SELF TEST FAILED SELF TEST NOT RECEIVING J1850 MESSAGE 6. To exit the self-check mode, depress the RESET button or cycle the ignition switch and the CMTC/EVIC will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAILED SELF TEST is displayed, the CMTC/EVIC must be replaced. Vehicle Information Display COMPASS/MINI-TRIP COMPUTER (CMTC) OR ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) When equipped, the Compass/Mini Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and the EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, instantaneous fuel economy, trip odometer, elapsed ignition ON time, distance to service, warning messages, and service messages. The EVIC also provides an interface to enable and disable vehicle programmable features and display memory system messages. If equipped, the CMTC or the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink. The CMTC and EVIC function buttons are labeled C/T, RESET, STEP and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. Most of the CMTC or EVIC display information is received over the PCI bus. The CMTC or EVIC sends and receives data over the PCI bus, communicating with the FCM, PCM, and the Instrument Cluster. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: Compass direction - Outside temperature - Elapsed ignition ON time - Distance to empty - Average fuel economy - Instantaneous fuel economy - Trip odometer - Distance to service - Driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CMTC or EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CMTC/EVIC. The CMTC/EVIC receives the following messages from the Instrument Cluster: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 218 - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Trip Odometer data - Elapsed Ignition On Time data - Fuel Economy (Average and Instantaneous) - Distance to Empty - Distance to service - Driver warning messages The EVIC transmits the following messages to the Instrument Cluster: Status Request: Beep, Reset, US/M Toggle - Current Display The CMTC/EVIC receives the following message from the PCM: Vehicle Speed STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: Average Fuel Economy Distance to Empty Instantaneous Fuel Economy Trip Odometer Time Elapsed Distance to Service Message Individual Tire Pressure Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF display. 3. To select the displayed programmable feature setting. MENU BUTTON Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the Instrument Cluster. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC Will reset ALL of the trip functions and an additional beep request is sent to the Instrument Cluster. The trip functions that may be reset are: Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the Instrument Cluster. Simultaneously pressing the RESET button and the C/T button while turning the ignition from OFF to ON will enter the CMTC/EVIC into the self-diagnostic mode. Compass/Temperature (C/T) Button Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. Traveler Display Functions Using the STEP button will change the CMTC/EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 219 Compass/Temperature The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC or EVIC module internally senses and calculates the compass direction. Compass Operation Upon ignition ON, if the calibration information stored in the CMTC/EVIC memory is within the normal range, the CMTC/EVIC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC/EVIC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC/EVIC memory is not within the normal range at ignition ON, the CMTC/EVIC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC/EVIC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. Ambient Temperature Sensor AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the CMTC/EVIC display indicates 54° C (130° F) or the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate a SHORT circuit condition. If the CMTC/EVIC display indicates -40° C (-40 ° F) or the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the EVIC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the EVIC temperature display is inoperative or incorrect, replace the FCM. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. Compass Calibration Compass Calibration The compass module has 2 types of auto-calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation the compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is ON and the CMTC/EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 220 - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance. - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/Temperature display. - Press and hold the RESET button until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360 degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn OFF. Setting Magnetic Zone Variance Setting Magnetic Zone Variance Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone, Follow these steps to check or change the variance zone: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the STEP button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. HOMELINK UNIVERSAL TRANSMITTER If equipped, the HomeLink Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink transmitter channel button is being pressed. The HomeLink can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink buttons are marked with one, two, or three dots. Homelink Universal Transmitter HOMELINK UNIVERSAL TRANSMITTER If equipped, the HomeLink Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink transmitter channel button is being pressed. The HomeLink can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink buttons are marked with one, two, or three dots. Door Ajar System DOOR AJAR SYSTEM The door ajar state is used as an input for various control modules on the vehicle. The DRB III will display the state of the door ajar switches in Inputs/Outputs. It's important to note, that when a door is closed, the switch state on the DRB III will show OPEN, and when the door is open, the switch state will show CLOSED. During diagnosis, if a door is closed and the DRB III displays the switch state as CLOSED, it indicates a shorted door ajar circuit. If the door is open and the DRB III displays the switch state as OPEN, it indicates an open door ajar circuit. Electrically Heated Systems ELECTRICALLY HEATED SYSTEMS HEATED MIRROR RELAY Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 221 A button located on the HVAC control head controls the Heated Mirror Relay, which is located in the IPM. The HVAC control will ground the Heated Mirror Relay Control circuit to energize this relay. The relay control circuit is continuously monitored for certain malfunctions that the HVAC will report as DTC's. Exterior Lighting System EXTERIOR LIGHTING SYSTEM The Instrument Cluster monitors the Headlamp Switch and Multifunctions Switch on its MUX line. The Instrument Cluster sends a PCI bus message to the Front Control Module (FCM) to actuate the Headlamps ON when the ignition switch is ON and when an open or short failure occurs on the headlamps switch input circuit to the instrument cluster. If the exterior lamps are left ON and the ignition switch OFF for more than 3 minutes, the Instrument Cluster will send a PCI bus message to the FCM to turn the exterior lamps OFF. This feature prevents the battery from being discharged when the Exterior Lamps have been left ON. Front Control Module FRONT CONTROL MODULE The Front Control Module (FCM) is a microprocessor-based electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives hard-wired analog and resistor multiplexed inputs as well as digital electronic inputs from other electronic modules in the vehicle electrical system through its connection to the IPM and the Programmable Communications Interface (PCI) data bus network. Based on these inputs and programming, the FCM uses high side drivers to provide direct power feeds and low side drivers to provide relay control for some of the vehicle's most critical electrical systems. The FCM provides the following features: Controlled Feeds Headlamp power Windshield washer pump motor Relay Controls Accessory relay Adjustable pedals relay (when equipped) Fog lamp relay (when equipped) Horn relay Park lamp relay Wiper ON/OFF relay Wiper high/low relay Electrical Inputs Headlamp battery supplies Module battery supply Power ground Ignition switch RUN or START position status Ignition switch START Only status PCI bus Brake lamp switch Wiper park switch Washer fluid level switch Brake fluid level switch Ambient Temperature sensor Right park lamp outage Left park lamp outage Battery IOD Battery (+) connection detection Flash reprogramming voltage Controlled Power Feeds Headlamp Power Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 222 he headlamp switch is a direct input to the instrument cluster which is sometimes known as the Cab Control Node (CCN). The instrument cluster sends a Programmable Communications Interface (PCI) bus message to the FCM informing it of a headlamp switch status change. The FCM then turns power ON or OFF (depending on the bus message) to the headlamps through four "fuseless" circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination levels. Washer Pump Motor The washer switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus message to the FCM informing it of a request to wash. The washer pump motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer pump motor from system voltages higher than 16 volts by automatically switching OFF the low side circuit. The low side circuit is connected to pin 45 in the FCM connector. If the FCM receives a prolonged request to wash lasting 30 seconds or more, it will treat the request as a stuck switch condition and deactivate the washer pump motor. The FCM will not reactivate the washer pump motor until there is at least a two second break in the request to wash from the instrument cluster. Relay Controls Accessory Relay The accessory relay works in conjunction with the FCM's power accessory delay features to control the operation of the radio, power windows, washer pump motors, wiper motor and power outlets. The accessory relay is turned ON by the FCM through the relay's low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain ON or will time out and deactivate. The accessory relay remains ON in the RUN and ACCY ignition switch positions. In the UNLK and OFF positions, the relay will remain energized for 45 seconds and then deactivate. During this time-out period, if a driver or passenger door is opened, the relay will be deenergized immediately. While the ignition switch is in the START position, the relay will also drop out and then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio. Adjustable Pedals Relay If equipped, the adjustable pedals relay, when not activated, supplies fused battery power to the adjustable pedals switch. If the FCM receives a bus message that the vehicle is in reverse or that the cruise control is engaged, it will apply a ground to the adjustable pedals relay control circuit. The ground will activate the relay which will open the power circuit to the adjustable pedals switch. The relay control circuit is continuously monitored for malfunctions which the FCM will report as DTC's. Fog Lamp Relay If equipped, the fog lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to turn ON the fog lamp relay. The fog lamp relay is then actuated by the FCM through low side control. This circuit is electronically controlled and continuously monitored for malfunctions. The FCM "learns" that the vehicle is equipped with fog lamps by reading the instrument cluster PCI bus message. Horn Relay The Horn Relay, which is internal to the IPM, is controlled by the FCM through PCI bus messages from the instrument cluster. These bus messages will be sent when either the horn switch is pressed which is hard wired to the instrument cluster, panic mode is requested from the RKE or for vehicle theft security reasons (if equipped). Under normal operating conditions, if the horn is activated for more than 30 seconds, the FCM will automatically deactivate the horn to prevent damage. The FCM will reactivate control of the relay after a 25-second cool-down period. The relay control circuit is continuously monitored for malfunctions that the FCM will report as DTC's. Park Lamp Relay The park lamp switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the park lamp relay. The park lamp relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper High/Low Relay The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/low relay. The relay switches power between the low speed and high speed brush of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. Wiper ON/OFF Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 223 The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper ON/OFF relay. The wiper ON/OFF relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. Electrical Inputs Headlamp Battery Supplies 12 Volt input as battery supply voltage dedicated for headlamp switching circuits only. Module Battery Supply 12 Volt input for all FCM functions except headlamp operation. Power Ground Ground source for all FCM functions Ignition Switch RUN or START Position Status 12 Volt input to inform the FCM of the ignition switch status for related FCM functions. Ignition Switch START Only Status 12 Volt input to allow the FCM to differentiate between the RUN/START and START only status for related FCM functions. PCI Bus Approximately 7.5 Volt input to allow the FCM to communicate with other modules on the PCI bus. Brake Lamp Switch Status 12 Volt input from brake lamp switch for brake shift interlock functions. Wiper Park Switch Ground input used to determine the park placement of the wipers. The ground is also used as feedback to the FCM to determine wiper operating mode. Washer Fluid Level Switch Ground input from the washer fluid level switch which closes when washer fluid is low. Right Park Lamp Outage 12 Volt input used to monitor the RH parking lamp circuit. Left Park Lamp Outage 12 Volt input used to monitor the LH parking lamp circuit. Battery IOD A low current 12 Volt input to maintain microprocessor power when the FCM switches to low power consumption mode during ignition OFF. Battery (+) Connection Detection 12 Volt supply used to monitor battery connection to the IPM. The battery connection to the IPM uses an internal switch to check integrity of the connection and that the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage is sent to the FCM to be interpreted as an unseated connector which will set a Diagnostic Trouble Code (DTC). Flash Programming Voltage 20 volt input. When the DRB III is connected and proper flash reprogramming sequence is selected, the 20 Volt signal will be applied to the FCM. Heating & A/C System HEATING & A/C SYSTEM System Availability Depending on the model, either a Single-Zone Air Conditioning System or Dual-Zone Air Conditioning System is available in these vehicles. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 224 System Controls The A/C-Heater Control Module: * is fully addressable with the DRB III. * communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. * uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. * provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. * controls blower motor operation, providing four blower speeds (Low, M1, M2, & High). * controls heated mirror operation. * controls electronic door actuator operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. The Single-Zone HVAC system uses: one, two-wire electronic blend door actuator. two, two-wire electronic mode door actuators. one, two-wire electronic recirculation door actuator. The Dual-Zone HVAC system uses: two, two-wire electronic blend door actuators. two, two-wire electronic mode door actuators. one, two-wire electronic recirculation door actuator. System Diagnostics Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) DTC's are displayed by the DRB III. Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. Stored DTC's are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: * Is actuated with the DRB III. * checks A/C system performance based on evaporator temperature sensor input. * will not run if ambient temperature is below 12.7° C (55° F). * will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. * faults display on the DRB III as test messages only after running the test. * faults will not display on the DRB III as Diagnostic Trouble Codes. * will cause the A/C mode switch status indicator to flash while the test is running. If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the EBL mode switch status indicator from indicating EBL operating status. However, the EBL mode switch will continue to function in this state. The EVAC Door Recalibration function: * is actuated with the DRB III. * monitors for faults on the actuator circuits. * faults display on the DRB III as test messages only after running the test. * faults will not display on the DRB III as Diagnostic Trouble Codes. * will cause the EBL mode switch status indicator to flash while the test is running. If the test fails, the status indicator will continue to flash until the test returns passed. It will also prevent the A/C mode switch status indicator from indicating A/C operating status. However, the A/C mode switch will continue to function in this state. The Actuator Circuit Test: * is actuated with the DRB III. * monitors for faults on the actuator circuits. * allows service to easily diagnose and troubleshoot up to three simultaneous shorts. * supplements the continuous diagnostics on the actuator drive system. * faults display on the DRB III as test messages only after running the test. * faults will not display on the DRB III as Diagnostic Trouble Codes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 225 When Performing The Actuator Circuit Test CAUTION: Shorted common door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause a fault. To ensure a proper diagnosis, repair all Short Too Complex messages first, all common door driver circuit related messages second, and all other door driver circuit related messages last. The DRB III can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. The Short Too Complex message: * indicates that a specific determination of which lines are shorted could not be made. * is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. Messages displaying: * xxx Driver/Circuit Shorted to Ignition/Battery will set on a per-driver basis. * XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. * the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together. After the Actuator Circuit Test is run on systems with less than six actuators: the actuator drive system is left in a state where further actuator positioning requests are ignored from both the panel and the DRB III. This state is cleared by cycling the ignition switch (cycling power to the control). If the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Interior Lighting INTERIOR LIGHTING The Instrument Cluster controls the Interior/Courtesy Lamps. The Instrument Cluster activates the courtesy lamps when either a Dome Lamp switch is turned ON or a door is opened. The Instrument Cluster also monitors the output of the Glove Box and Map lamps. The Cargo lamps are controlled by the Instrument Cluster, it receives an output message from the Headlamp switch to turn ON the lamps. The Instrument Cluster provides battery protection by shutting down the interior lamps when a door or courtesy/map lamp is left on or open. Mechanical Instrument Cluster (MIC) INSTRUMENT CLUSTER The DR Instrument Cluster is a new type of control module that includes the hardware and software necessary to function as the cluster and the body control module. The Instrument Cluster houses the Speedometer, Tachometer, Fuel gauge, Coolant Temperature gauge, Oil Pressure gauge, and the Voltage gauge. The cluster positions all of the gauges using PCI bus messages received from the PCM. The cluster contains certain warning indicators, depending on engine type and options. Some of the indicators are hardwire inputs and some indicators are controlled via PCI bus messages. The warning chime tone generator is contained within the cluster. The cluster includes a Vacuum Fluorescent (VF) display for the PRNDL, Total and Trip Odometers. The VF will also display warning messages such as door ajar, low washer fluid level, engine hours, and no bus communications. The cluster has the ability to set and store DTC's, communicate on the PCI bus, display engine information, and display certain inputs using the DRB III. The following systems are controlled either completely by the Instrument Cluster or in conjunction with other inputs received by hardwire or via the PCI bus: * Audible Warnings * Brake Lamp Control * Brake Transmission Shift Interlock (BTSI) * Cargo Lamp Control * Central Locking * Door Lock Inhibit * Enhanced Accident Response * Exterior Lighting Control * Exterior Lighting Fail-Safe * Heated Seat Control * Interior Lamp Control * Interior Lamps - Enhanced Accident Response * Interior Lamps Load Shedding * Lamp Out Indicator Control * Panel Lamps Dimming Control * Parade Mode Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 226 * Power Locks * Remote Keyless Entry (RKE) * Remote Radio Switch Interface * Rolling Door Locks * Turn Signal and Hazard Warning Lamp Control * Vacuum Fluorescent Display Synchronization * Vehicle Theft Security System (VTSS) CAUTION: Instrument clusters used in this model automatically configure themselves for compatibility with the features and optional equipment in the vehicle in which they are initially installed. The instrument cluster is programmed to do this by embedding the Vehicle Identification Number (VIN) and other information critical to proper cluster operation in electronic memory. This embedded information is learned through electronic messages received from other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus, and through certain hard wired inputs received when the cluster is connected to the vehicle electrically. Once configured, the instrument cluster memory may be irreparably damaged and certain irreversible configuration errors may occur if the cluster is connected electrically to another vehicle; or, if an electronic module from another vehicle is connected that provides data to the instrument cluster (including odometer values) that conflicts with that which was previously learned and stored. Therefore, the practice of exchanging (swapping) instrument clusters and other electronic modules in this vehicle with those removed from another vehicle must always be avoided. Failure to observe this caution may result in instrument cluster damage, which is not reimbursable under the terms of' the product warranty. Service replacement instrument clusters are provided with the correct VIN, and the certified odometer and engine hours values embedded in cluster memory, but will otherwise be automatically configured for compatibility with the features and optional equipment in the vehicle in which they are initially installed. Diagnostic Self Test The Instrument Cluster is capable of performing a Diagnostic Self Test. This self test can be initiated manually by depressing and holding the trip reset button while cycling the ignition from the Off to the On position. The self test can also be activated using the DRB III. During the self test, all of the PCI bus indicators will be illuminated. The speedometer, tachometer, fuel gauge, oil pressure gauge, coolant temperature gauge, and voltage gauge will position at their calibration points. The VF display will illuminate all segments and also display the software version. The chime will sound. When the self test is complete, the cluster will return to normal operation. Turning the ignition to the Off position or the cluster detecting engine RPM greater than 0 (zero) will stop the self test. Power Door Locks/Remote Keyless Entry POWER DOOR LOCKS/REMOTE KEYLESS ENTRY The Instrument Cluster in response to the door lock switches or the RKE module directly controls the power door lock motors. The Instrument Cluster monitors the activation of the door lock motors and will set diagnostic trouble codes when there is an open or short condition. When there is a lock or unlock input from a switch or RKE command, the Instrument Cluster will activate the appropriate driver for 300 milliseconds. If a lock or unlock switch remains active, the request will be ignored until the switch transitions back to OFF, The lock switches are resistive multiplexed input devices hardwired to the Instrument Cluster. Automatic Door Locks The Instrument Cluster will automatically lock all the doors when the vehicle speed exceeds 15 MPH (24 KMH), throttle position exceeds 10 percent and all the doors are closed. If a door is opened the Automatic Door Lock feature shall reset and the Instrument Cluster will lock the doors when the above conditions are met. This feature is programmable by the customer or the DRB III. Central Locking/Unlocking The Instrument Cluster Will lock all doors when a cylinder lock switch is activated in the "lock" position. When the Instrument Cluster receives an unlock command from one of the cylinder lock switches, it will unlock only that door. If the Instrument Cluster receives a second command within a 5-second period it will unlock all the remaining doors. The illuminated entry will activate during door unlock. Door Lock Inhibit When the key is in the ignition, in any position, and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE transmitter will still lock the doors as usual. Enhanced Accident Response Upon detection of an airbag deployment by way of the PCI bus, the Instrument Cluster shall: Immediately disable the power door lock output Unlock all doors by activating the door unlock output for approximately 300 milliseconds. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 227 After actuating the door unlock output, allow the door lock motors to be activated if the door lock input has been inactive (not erratic) for 2 seconds since the reception of the airbag deployment message. REMOTE KEYLESS ENTRY The remote keyless entry (RKE) feature is used to control the power door locks and panic feature by using a remote transmitter (keylob) and receiver located within the instrument cluster. The instrument cluster RKE feature controls the driver door unlock, all doors lock/unlock, horn chirp enabled/disable, optical chirp enabled/disable, illuminated entry, the panic feature, initiate customer programming, and arming/disarming the Vehicle Theft Security System. When a valid lock message is received from the receiver, the instrument cluster will: Arm the Vehicle Theft Security System (if equipped and all conditions are met). Turn OFF the illuminated entry feature. Activate the door lock motors. Transmit a PCI bus message to the FCM to perform horn chirp. When a valid unlock code is received from the receiver, the instrument cluster will: Disarm the Vehicle Theft Security System (if equipped and previously set). Activate the illuminated entry and cargo lamp. Activate the driver door unlock motor (if customer programmed for driver door only unlock). Transmit a PCI bus message to the FCM for optical chirp. Vehicle Theft Security System VEHICLE THEFT SECURITY SYSTEM The Instrument Cluster controls the Vehicle Theft Security System (VTSS) and enables VTSS itself from the presence of Sentry Key Immobilizer module PCI bus messages. When the VTSS is armed it will monitor the status of the ignition and door ajar switches. If the alarm is tripped it will sound the vehicles horn, flash the exterior lamps and the VTSS indicator located in the instrument cluster. Arming the system is accomplished following a normal exit sequence of removing the key from the ignition, opening the door pressing the power lock button to lock and closing the door, by using a cylinder lock switch or by pressing the RKE lock button. After all the doors are closed, the VTSS indicator will flash quickly for sixteen-seconds indicating the pre-arm process, after which it will flash at a slower rate indicating the system is armed. If during the pre-arm process a door is opened, the ignition is turned to the Run/Start position or if a RKE unlock button is pressed the system will exit the pre-arming process. Disarming can be accomplished with a RKE unlock, turning the ignition ON with a valid Sentry key or unlocking the vehicle with a cylinder lock switch. The Alarming state will last for 18 minutes after which it will timeout and return to the armed state. A tamper alert feature will alert the customer to the alarm being tripped while they were away upon returning to the vehicle by flashing the VTSS indicator for 30 seconds after the system has been disarmed. All of the switches for the VTSS system can be monitored using the DRB III. The DRB III is also useful for a customer complaint of the alarm going OFF with no apparent reason by viewing the VTSS last alarm caused by display. Windshield Wipers/Washers WINDSHIELD WIPERS/WASHERS The Instrument Cluster controls the wiper/washer system. The instrument cluster receives a signal from the Multifunction Switch wipe position. The instrument cluster sends the message to the Front Control Module (FCM), sending the command to turn the wiper/washers ON. Two relays, the High/Low relay and the ON/OFF relay also control the wipers. Both are located in the PDC or Integrated Power Module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Body Control Module: Reading and Clearing Diagnostic Trouble Codes Displaying and Reading Trouble Codes USING THE DRB III Refer to the DRB III user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB III functions. DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot or User Requested COLD Boot. If the DRB III( R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. User-Requested WARM Boot by pressing MORE and NO at the same time. ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: Ox1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. - OR User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line: 1297 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 230 DRB III(R) Scan Tool Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Clearing Trouble Codes NOTE: This is the only information provided by the manufacturer for clearing codes for this system. USING THE DRB III Refer to the DRB III user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB III functions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 231 Body Control Module: Symptom Related Diagnostic Procedures Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRB III - Instrument cluster - Chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 232 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 233 Tests 1 - 3 Tests 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Vehicle Speed Warning Chime Problem Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 234 Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 235 Body Control Module: Testing and Inspection Displaying and Reading Trouble Codes USING THE DRB III Refer to the DRB III user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB III functions. DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot or User Requested COLD Boot. If the DRB III( R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display. User-Requested WARM Boot by pressing MORE and NO at the same time. ver: 2.29 date: 1 Oct 93 file: key_itf.cc date: Jan 12 1994 line: 544 err: Ox1 User-Requested WARM Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. - OR User-Requested COLD Boot by pressing MORE and YES at the same time. ver: 2.29 date: 1 Oct 99 file: keyhnd1.cc date: Mar 8 2000 line: 1297 err: Ox1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III Does Not Power Up If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. Check for proper ground connection at DLC cavities 4 and 5. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III may be the result of faulty cable or vehicle wiring. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 236 DRB III(R) Scan Tool Display Is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Clearing Trouble Codes NOTE: This is the only information provided by the manufacturer for clearing codes for this system. USING THE DRB III Refer to the DRB III user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB III functions. Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Chime Inoperative Test 1 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Actuate chime with DRB III - Instrument cluster - Chime inoperative Chime Sounds With Drivers Door Open and Key Removed From Ignition Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 237 Tests 1 - 4 SYMPTOM CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED POSSIBLE CAUSES - Key-in IGN SW status - Key-in ignition switch shorted - Key-in ignition SW sense short to ground - Instrument cluster Key In Ignition and Drivers Door Open Chime Inoperative Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 238 Tests 1 - 3 Tests 4 - 5 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE POSSIBLE CAUSES - Observe the key-in ignition switch status - Key-in ignition switch open - Key-in ignition switch ground circuit open - Key-in ignition switch sense circuit open - Instrument cluster - incorrect key-in ignition switch status Vehicle Speed Warning Chime Problem Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 239 Test 1 SYMPTOM VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in instrument cluster - Instrument cluster Road Testing A Complaint Vehicle ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB III screen while in motion. Do not hang the DRB III from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB III. Six Step Troubleshooting Procedure SIX-STEP TROUBLESHOOTING PROCEDURE Diagnosis is done in six basic steps: 1. Verification of complaint 2. Verification of any related symptoms 3. Symptom analysis 4. Problem isolation 5. Repair of isolated problem 6. Verification of proper operation Vehicle Preparation For Testing VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms GLOSSARY OF TERMS ABS ............................................................................................................. ..................................................................................... Antilock Brake System ACM........................... .............................................................................................................................................................. .........Airbag Control Module AECM..................................................................................................... ..............................................................Airbag Electronic Control Module (ACM) ASDM.................... ...............................................................................................................................................Airbag System Diagnostic Module (ACM) BCM............................................................................................... .......................................................................................................Body Control Module BTSI............ .............................................................................................................................................................. ........Brake Transmission Shift Interlock CAB....................................................................................... .........................................................................................................Controller Antilock Brake CMTC.. .............................................................................................................................................................. ......................Compass/Mini-Trip Computer CPA................................................................................ ...........................................................................................................Connector Positive Assurance DAB...................................................................................................................................................... ..............................................................Driver Airbag DLC.................................................................. .......................................................................................................................................Data Link Connector DTC..................................................................................................................................... .............................................................Diagnostic Trouble Code EMIC............................................... ......................................................................................................................... Electro Mechanical Instrument Cluster EBL........................................................................................................................ ............................................Electric Back Lite (rear Window De-fogger) EVIC.................................... ........................................................................................................................................Electronic Vehicle Information Center FCM.......................................................................................................... ............................................................................................Front Control Module HVAC..................... .......................................................................................................................................................Hea ter Ventilation, Air Conditioning Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 240 IC.......................................................................................................................................................... ...........................................Instrument Cluster (MIC) IPM.................................................................... ..............................................................................................................................Integrated Power Module JB............................................................................................................................................. .........................................................................Junction Block MIC...................................................... ...................................................................................................................................Mechanical Instrument Cluster ODO....................................................................................................................... ...................................................................................................Odometer ORC.................................. ........................................................................................................................................................Oc cupant Restraint Controller PAB........................................................................................................... ....................................................................................................Passenger Airbag PCI..........................................................................................................................Programmable Communication Interface (Vehicle Communication Bus) PCM............................................................ ..................................................................................................................................Powertrain Control Module PDC............................................................................................................................. ....................................................................Power Distribution Center PWM....................................... ............................................................................................................................................................ Pulse Width Modulated RKE................................................................................................................ ......................................................................................Remote Keyless Entry SBS............................ .............................................................................................................................................................. .......................Seat Belt Switch SBT.................................................................................................... ........................................................................................................Seat Belt Tensioner SIACM.......... .............................................................................................................................................................. ....Side Impact Airbag Control Module SKIM........................................................................................ ............................................................................................Sentry Key Immobilizer Module SKIS....... .............................................................................................................................................................. ..................Sentry Key Immobilizer System SRS................................................................................. .........................................................................................................Supplemental Restraint System SUV...................................................................................................................................................... ...................................................Sport Utility Vehicle TCCM................................................................ ......................................................................................................................Transfer Case Control Module TCM......................................................................................................................................... ................................................Transmission Control Module UGDO................................................... ..................................................................................................................................Universal Garage Door Opener VFD................................................................................................................................. ...........................................................Vacuum Fluorescent Display VTSS.......................................... ..............................................................................................................................................Vehicle Theft Security System Scan Tool Testing and Procedures DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB III will display one of only two error messages: User-Requested WARM Boot (Press MORE and NO at the same time) User-Requested COLD Boot (Press MORE and YES at the same time) If the DRB III should display any other error message, record the entire display and call the S.T.A.R. Center for information and assistance. DRB III DOES NOT POWER UP If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB III. If all connections are proper between the DRB III and the vehicle or other devices, and the vehicle battery is fully charged, and inoperative DRB III Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 241 may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition SOME DISPLAY ITEMS READ "---" This is caused by scrolling the DRB III display a single line up or down. The line which was scrolled onto the screen might read "---". Use the Page Down or Page Up function to display the information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 242 Body Control Module: Service and Repair FRONT CONTROL MODULE REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the integrated power module from the engine compartment (Refer to POWER DISTRIBUTION/INTEGRATED POWER MODULE - REMOVAL). 3. Remove the front control module retaining screws. 4. Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector and remove the front control module from the vehicle. INSTALLATION 1. Install the front control module on the integrated power module assembly by pushing the 49-way electrical connector straight in. 2. Install the front control module retaining screws. Torque the screws to 7 in. lbs. 3. Install the integrated power module (Refer to POWER DISTRIBUTION/INTEGRATED POWER MODULE - INSTALLATION). 4. Connect the positive and negative battery cables. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 243 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool Diagnostic Junction Port Tester 8339 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 248 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 249 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 250 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 251 Engine Control Module: Specifications Powertrain Control Module Mounting Bolts ............................................................................................................................................. 4 Nm (35 in. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 252 Engine Control Module: Locations Fig. 3 Powertrain Control Module (PCM) Location The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 263 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 264 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 265 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 267 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 268 Engine Control Module: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 270 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 271 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 273 Powertrain Control Module C2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Powertrain Control Module C3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Engine Control Module: Electrical Diagrams System Diagrams Refer to Powertrain Management/Diagrams/Electrical for wiring diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams System Schematic 5.9L Federal Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 276 5.9L California Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description Engine Control Module: Description and Operation Description Fig. 3 Powertrain Control Module (PCM) Location POWERTRAIN CONTROL MODULE The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. The PCM is referred to as JTEC . The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 279 - Crankshaft position sensor - Data link connection for DRB scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in ON/OFF/ crank/run position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - 5 volt sensor supply (primary) - 5 volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 280 Engine Control Module: Description and Operation Modes of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for Wide Open Throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O(2)S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the Oxygen (O(2)S) Sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O(2)S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Ignition Switch (Key-ON) Mode This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle Position Sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O(2)S sensor heater element is energized via the ASD or O(2)S heater relay. The O(2)S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. Engine Start-up Mode This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 281 Engine Warm-up Mode This is an Open Loop mode. During engine warmup, the PCM receives inputs from: Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning for additional information. - When engine has reached operating temperature, the PCM will begin monitoring O(2)S sensor input. The system will then leave the warm-up mode and go into closed loop operation. Idle Mode When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal~auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. - The PCM monitors the O(2)S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning for additional information. Cruise Mode When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O(2)S) sensors Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector ON and OFF. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 282 - The PCM monitors the O(2)S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) ON and OFF. - The PCM operates the A/C compressor clutch through the clutch relay This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. Acceleration Mode This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. Deceleration Mode When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-OFF strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil ON and OFF. Wide Open Throttle Mode This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector ON and OFF. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) ON and OFF. Ignition Switch OFF Mode When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Power- train Control Module (PCM). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Description > Page 283 The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 284 Engine Control Module: Service and Repair REMOVAL USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. Fig. 4 PCM Location The PCM is located in the engine compartment attached to the dash panel. To avoid possible voltage spike damage to the PCM, ignition key must be off and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 285 Fig. 5 PCM Removal/Installation 3. Carefully unplug the three 32-way connectors from PCM. 4. Remove three PCM mounting bolts and remove PCM from vehicle. INSTALLATION USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Install PCM and 3 mounting bolts to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors. 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable 7. Use the DRB scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 289 Main Relay (Computer/Fuel System): Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 290 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 291 Auto Shut Down Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 292 Main Relay (Computer/Fuel System): Description and Operation AUTOMATIC SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 293 Main Relay (Computer/Fuel System): Testing and Inspection ASD RELAY Fig. 1 Type 1 Relay (ISO Micro Relay) Fig. 2 ASD And Fuel Pump Relay Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 294 The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 295 Main Relay (Computer/Fuel System): Service and Repair Fig. 3 PDC Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 299 Oxygen Sensor Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 300 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 301 Oxygen Sensor Downstream Relay (California) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Locations > Page 302 Oxygen Sensor Relay: Description and Operation Oxygen Sensor Heater Relay: If the vehicle is equipped with 4 oxygen sensors, a separate oxygen sensor relay is used to supply voltage to the sensor heating elements. This particular relay is used only for the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the ASD relay. Refer to Wiring Diagrams to determine which relay is used. See: Diagrams/Electrical Diagrams To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heaters/Heater Relays: Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Wiring Diagrams to determine which relays are used.See: Relays and Modules - Power and Ground Distribution/Relay BoxApplications and ID. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 307 Fig. 16 PDC Location The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 310 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 311 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 312 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 313 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 314 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 315 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 316 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 318 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 319 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 320 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Fuel Pump Relay: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 324 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 325 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 326 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Fuel Pump Relay: Connector Views 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 328 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 329 Fuel Pump Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 330 Fuel Pump Relay: Description and Operation The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location. The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1 - 3 seconds unless the engine is operating or the starter motor is engaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 331 Fuel Pump Relay: Testing and Inspection ASD AND FUEL PUMP RELAYS Fig. 1 Type 1 Relay (ISO Micro Relay) Fig. 2 ASD And Fuel Pump Relay Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, (Fig. 1) or (Fig. 2). Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 332 The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 333 Fuel Pump Relay: Service and Repair Fig. 16 PDC Location REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 16). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 337 Main Relay (Computer/Fuel System): Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 338 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 339 Auto Shut Down Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 340 Main Relay (Computer/Fuel System): Description and Operation AUTOMATIC SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 341 Main Relay (Computer/Fuel System): Testing and Inspection ASD RELAY Fig. 1 Type 1 Relay (ISO Micro Relay) Fig. 2 ASD And Fuel Pump Relay Terminals - Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 342 The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Wiring Diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 343 Main Relay (Computer/Fuel System): Service and Repair Fig. 3 PDC Location REMOVAL The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation IGNITION CONTROL Two different ignition Systems are used One type of system is used on both the 3.7L V 6 and the 4.7L V-8 engine. The other is used on the 5.9L V-8 engine. The 5.9L ignition system will use a conventional distributor and remotely mounted coil. The 3.7L V-6 and 4.7L V-8 engines will not use a distributor. The 3.7L /4.7L is also equipped with separate and independent ignition coils. 3.7L V-6 The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 3.7L V-6 engine uses a separate ignition coil for each cylinder. The one-piece coil bolts directly to the cylinder head. Rubber boots seal the secondary terminal ends of the coils to the top of all 6 spark plugs. A separate electrical connector is used for each coil. Because of coil design, spark plug cables (secondary cables) are not used. A distributor is not used with the 3.7L engine. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The Auto Shutdown (ASD) relay provides battery voltage to each ignition coil. The Powertrain Control Module (PCM) provides a ground contact (circuit) for energizing each coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing a spark. The PCM will de-energize the ASD relay if it does not receive inputs from either the crankshaft or camshaft position sensors. 4.7L V-8 The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 4.7L V-8 engine uses a separate ignition coil for each cylinder. The one-piece coil bolts directly to the cylinder head. Rubber boots seal the secondary terminal ends of the coils to the top of all 8 spark plugs. A separate electrical connector is used for each coil. Because of coil design, spark plug cables (secondary cables) are not used. A distributor is not used with the 4.7L engine. The Auto Shutdown (ASD) relay provides battery voltage to each ignition coil. The Powertrain Control Module (PCM) provides a ground contact (circuit) for energizing each coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing a spark. The PCM will de-energize the ASD relay if it does not receive inputs from either the crankshaft or camshaft position sensors. 5.9L V-8 The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The ignition system consists of: 8 Spark Plugs - 1 Ignition Coil - Secondary Ignition Cables - Distributor (contains rotor and camshaft position sensor) - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position and MAP Sensors. AUTOMATIC SHUT DOWN RELAY PCM Output The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit ON and OFF. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 348 This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). CAMSHAFT POSITION SENSOR 3.7L The Camshaft Position Sensor (CMP) on the 3.7L 6-cylinder engine is bolted to the right-front side of the right cylinder head. Fig. 4 CMP Operation - 3.7L The Camshaft Position Sensor (CMP) sensor on the 3.7L V-6 engine contains a hall effect device referred to as a sync signal generator. A rotating target wheel (tonewheel) for the CMP is located at the front of the camshaft for the right cylinder head. This sync signal generator detects notches located on a tonewheel. As the tonewheel rotates, the notches pass through the sync signal generator. The signal from the CMP sensor is used in conjunction with the Crankshaft Position Sensor (CKP) to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the tonewheel notch enters the tip of the CMP, the interruption of magnetic field causes the voltage to switch high, resulting in a sync signal of approximately 5 volts. When the trailing edge of the tonewheel notch leaves then tip of the CMP; the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. 4.7L The Camshaft Position Sensor (CMP) on the 4.7L V-8 engine is bolted to the right-front side of the right cylinder head. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 349 Fig. 5 CMP And Tonewheel Operation - 4.7L The CMP sensor on the 4.7L engine contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tone- wheel is located at the front of the camshaft for the right cylinder head. As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. 5.9L The Camshaft Position Sensor (CMP) on the 5.9L V-8 engine is located inside the distributor. Fig. 6 CMP / Pulse Ring - 5.9L The CMP sensor on the 5.9L V-8 engine contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the Crankshaft Position (CKP) sensor to differentiate between fuel injection and spark events. It is also used to Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 350 synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Fig. 10 Distributor And Camshaft Position Sensor - 5.9L DISTRIBUTOR All these engines are equipped with a camshaft driven mechanical distributor containing a shaft driven distributor rotor. All distributors are equipped with an internal camshaft position (fuel sync) sensor. The distributor does not have built in centrifugal or vacuum assisted advance. Base ignition timing and all timing advance is controlled by the Powertrain Control Module (PCM). Because ignition timing is controlled by the PCM, base ignition timing is not adjustable. The distributor is held to the engine in the conventional method using a holddown clamp and bolt. Although the distributor can be rotated, it will have no effect on ignition timing. All distributors contain an internal oil seal that prevents oil from entering the distributor housing. The seal is not serviceable. IGNITION COIL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 351 Fig. 17 Ignition Coil - 3.7L / 4.7L Fig. 18 Ignition Coil Location - 3.7L 3.7L The 3.7L V-6 engine uses 6 dedicated, and individually fired coil for each spark plug. Each coil is mounted directly into the cylinder head and onto the top of each spark plug. Battery voltage is supplied to the 6 individual ignition coils from the ASD relay. The Powertrain Control Module (PCM) opens and closes each ignition coil ground circuit at a determined time for ignition coil operation. Base ignition timing is not adjustable. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 352 Because of coil design, spark plug cables (secondary cables) are not used with the 3.7L engine. Fig. 19 Ignition Coil Location - 4.7L 4.7L The 4.7L V-8 engine uses 8 dedicated, and individually fired coil for each spark plug. Each coil is mounted directly to the top of each spark plug. Battery voltage is supplied to the 8 individual ignition coils from the ASD relay. The Powertrain Control Module (PCM) opens and closes each ignition coil ground circuit at a determined time for ignition coil operation. Base ignition timing is not adjustable. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. Because of coil design, spark plug cables (secondary cables) are not used with the 4.7L engine. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 353 Fig. 20 Ignition Coil Location - 5.9L 5.9L A single ignition coil is used. The coil is not oil filled. The coil windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the coil to be mounted on the engine. A single ignition coil is used. The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Battery voltage is supplied to the ignition coil positive terminal from the ASD relay. If the PCM does not see a signal from the crankshaft and camshaft sensors (indicating the ignition key is ON but the engine is not running), it will shut down the ASD circuit. Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. KNOCK SENSOR The 2 knock sensors are bolted into the cylinder block under the intake manifold. The sensors are used only with the 3.7L engine. Two knock sensors are used on the 3.7L V-6 engine; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. SPARK PLUG Resistor type spark plugs are used. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. Inaccurate readings will result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation > Page 354 To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. IGNITION COIL CAPACITOR One coil capacitor is used. It is located in the right- rear section of the engine compartment. The coil capacitor(s) help dampen the amount of conducted electrical noise to the camshaft position sensor, crankshaft position sensor, and throttle position sensor. This noise is generated on the 12V supply wire to the ignition coils and fuel injectors. SPARK PLUG CABLE Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 359 Air Bag Control Module: Diagrams Airbag Control Module Airbag Control Module - Left Side Impact Airbag Control Module - Right Side Impact Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 362 Air Bag Control Module: Vehicle Damage Warnings WARNING: NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) Air Bag Control Module: Description and Operation Airbag Control Module (ACM) WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. - BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. - THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT Fig. 7 Airbag Control Module AIRBAG CONTROL MODULE The Airbag Control Module (ACM) is secured with four screws to the top mounting surface of a stamped steel bracket welded onto the top of the floor panel transmission tunnel forward of the instrument panel center support bracket and below the instrument panel center stack in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ACM housing is the electronic circuitry of the ACM which includes a microprocessor, an electronic impact sensor, an electromechanical safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ACM housing with four screws to enclose and protect the internal electronic circuitry and components. The ACM housing has integral mounting flanges on each side. Two of the mounting flanges, one on each side, have an integral locating pin on their lower surface. The left flanges have round mounting holes, while the flanges on the right side have slotted mounting holes. An arrow cast into the top of the ACM housing near the rear provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. A molded plastic electrical connector receptacle containing twenty-three terminal pins exits the rearward facing side of the ACM housing. These terminal pins connect the ACM to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The impact sensor and safing sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. The ACM cannot be repaired or adjusted and, if damaged or faulty it must be replaced. The microprocessor in the Airbag Control Module (ACM) contains the front supplemental restraint system logic circuits and controls all of the front supplemental restraint system components. The ACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. (Refer to INSTRUMENT CLUSTER/AIRBAG INDICATOR - OPERATION). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 365 The ACM microprocessor continuously monitors all of the front supplemental restraint system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault or in some cases the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the ACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab models, the ACM also monitors inputs from the passenger airbag on/off switch. On models equipped with optional side curtain airbags, the ACM communicates with both the left and right Side Impact Airbag Control Modules (SIACM) over the PCI data bus. The SIACM notifies the ACM when it has detected a monitored system fault and stored a DTC in memory for its respective side curtain airbag system, and the ACM sets a DTC and controls the airbag indicator operation accordingly. The ACM receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Integrated Power Module (IPM), and a fused ignition switch output (run-start) circuit through a second fuse in the IPM. The ACM receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel support structure. These connections allow the ACM to be operational whenever the ignition switch is in the Start or ON positions. The ACM also contains an energy-storage capacitor. When the ignition switch is in the Start or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the front supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ACM during an impact. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electromechanical sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is a normally open switch that is used to verify the need for a front supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the front airbags or seat belt tensioners to deploy. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor and the safing sensor indicate an impact that is severe enough to require front supplemental restraint system protection and, based upon the status of the passenger airbag on/off switch input and the severity of the monitored impact, determines what combination of seat belt tensioner and front airbag deployment is required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the seat belt tensioners and dual front airbags. The hard wired inputs and outputs for the ACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ACM, the PCI data bus network, or the electronic message inputs to and outputs from the ACM. The most reliable, efficient, and accurate means to diagnose the ACM, the PCI data bus network, and the electronic message inputs to and outputs from the ACM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 366 Air Bag Control Module: Description and Operation Side Impact Airbag Control Module (SIACM) WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT Fig. 53 Side Impact Airbag Control Module SIDE IMPACT AIRBAG CONTROL MODULE Supplemental driver and front passenger curtain airbags provide side impact protection for the front and rear seat occupants. Each curtain airbag has its own side impact airbag control module (SIACM) to provide independent impact sensing and deployment. SIACM are located on the left and right B post just below the seat belt retractor. The SIACM performs self diagnostics and circuit tests to determine if the system is functioning properly. If the test finds a problem the SIACM will set both active and stored diagnostic trouble codes. The results of the system test are transmitted on the PCI Bus to the ACM once each second. If the warning lamp status message from either SIACM contains a lamp ON request, the ACM will set an active DTC. At the same time as the DTC is set the ACM sends a PCI Bus message to the mechanical instrument cluster (MIC) requesting the airbag warning lamp be turned ON. Observe all ACM warning and caution statements when servicing or handling the SIACM. SIACM are not repairable and must be replaced if they are dropped. On vehicles equipped with the optional side curtain airbags, a Side Impact Airbag Control Module (SIACM) and its mounting bracket are secured with four screws to the inside of each B-pillar behind (standard cab) or above (quad cab) the front outboard seat belt retractor, and concealed behind the B-pillar trim. Concealed within a hollow in the center of the die cast aluminum SIACM housing is the electronic circuitry of the SIACM which includes a microprocessor and an electronic impact sensor. The SIACM housing is secured to a die cast (standard cab) or stamped steel (quad cab) mounting bracket, which is unique for the right or left side application of this component. The SIACM should never be removed from its mounting bracket. The housing also receives a case ground through this mounting bracket when it is secured to the vehicle. A molded plastic electrical connector receptacle that exits the top of the SIACM housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Both the SIACM housing and its electrical connection are sealed to protect the internal electronic circuitry and components against moisture intrusion. The impact sensor internal to the SIACM is calibrated for the specific vehicle, and is only serviced as a unit with the SIACM. The SIACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Airbag Control Module (ACM) > Page 367 The microprocessor in the Side Impact Airbag Control Module (SIACM) contains the side curtain airbag system logic circuits and controls all of the features of only the side curtain airbag mounted on the same side of the vehicle as the SIACM. The SIACM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the DRB III scan tool using the Programmable Communications Interface (PCI) data bus network. This method of communication is used by the SIACM to communicate with the Airbag Control Module (ACM) and for supplemental restraint system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ACM communicates with both the left and right SIACM over the PCI data bus. The SIACM microprocessor continuously monitors all of the side curtain airbag electrical circuits to determine the system readiness. If the SIACM detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the ACM over the PCI data bus. The ACM will respond by sending an electronic message to the EMIC to turn on the airbag indicator, and by storing a DTC that will indicate whether the left or the right SIACM has stored the DTC that initiated the airbag indicator illumination. An active fault only remains for the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the SIACM. For some DTCs, if a fault does not recur for a number of ignition cycles, the SIACM will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The SIACM receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Integrated Power Module (IPM). The SIACM has a case ground through its mounting bracket and also receives a power ground through a ground circuit and take out of the body wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the body sheet metal. These connections allow the SIACM to be operational whenever the ignition switch is in the Start or On positions. An electronic impact sensor is contained within the SIACM. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the SIACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates a side impact that is severe enough to require side curtain airbag protection. When the programmed conditions are met, the SIACM sends the proper electrical signals to deploy the side curtain airbag. The hard wired inputs and outputs for the SIACM may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SIACM, the PCI data bus network, or the electronic message inputs to and outputs from the SIACM. The most reliable, efficient, and accurate means to diagnose the SIACM, the PCI data bus network, and the electronic message inputs to and outputs from the SIACM requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover Air Bag Control Module: Service and Repair ACM Cover REMOVAL The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be removed to access the ACM for service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. Fig. 6 ACM Cover Remove/Install 2. Using a trim stick or another suitable wide flat-bladed tool, gently pry each side of the ACM cover away from the instrument panel far enough to disengage the two snap clip retainers from the instrument panel receptacles. 3. Remove the ACM cover from the instrument panel. INSTALLATION The Airbag Control Module (ACM) cover is used only on models with an automatic transmission. Models with a manual transmission require that the floor console be reinstalled following ACM service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the ACM cover to the instrument panel. 2. Align the two snap clip retainers on the ACM cover with the receptacle on each side of the instrument panel. 3. Using hand pressure, press firmly and evenly on the outside of the ACM cover over each snap clip retainer location until each retainer is fully engaged in its instrument panel receptacle 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 370 Air Bag Control Module: Service and Repair Airbag Control Module REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. On models with a manual transmission, remove the floor console from the top of the floor panel transmission tunnel. 3. On models with an automatic transmission, remove the ACM cover from the instrument panel. (Refer to RESTRAINTS/ACM COVER REMOVAL). Fig. 8 Airbag Control Module Remove/Install 4. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and disconnect the instrument panel wire harness connector for the Airbag Control Module (ACM) from the connector receptacle located on the rearward facing side of the module. To disconnect the instrument panel wire harness connector from the ACM: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the connector straight away from the ACM connector receptacle. 5. From the right side of the floor panel transmission tunnel, loosen each of the two screws that secure the right side of the ACM to the bracket on the floor panel transmission tunnel about 7 millimeters (0.25 inch). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 371 6. From the left side of the floor panel transmission tunnel, remove the two screws that secure the left side of the ACM to the bracket on the floor panel transmission tunnel. 7. Still working from the left side of the floor panel transmission tunnel, lift the ACM upward far enough to disengage the locating pins on the bottom of the ACM mounting flanges from the locating holes in the bracket, then slide the ACM toward the left far enough to disengage the slotted holes in the right ACM mounting flanges from under the heads of the two previously loosened right mounting screws. 8. Remove the ACM from the left side of the floor panel transmission tunnel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. NEVER STRIKE OR DROP THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Airbag Control Module (ACM) to the left side of the floor panel transmission tunnel near the ACM bracket. When the ACM is correctly positioned, the arrow on the ACM housing will be pointed forward in the vehicle. 2. From the left side of the floor panel transmission tunnel, slide the ACM toward the right far enough to engage the slotted holes in the right ACM mounting flanges under the heads of the two previously loosened right mounting screws, then engage the locating pins on the bottom of the ACM mounting flanges into the locating holes in the bracket. 3. Still working from the left side of the floor panel transmission tunnel, install and tighten the two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 14 Nm (10 ft. lbs.). 4. From the right side of the floor panel transmission tunnel, tighten each of the two screws that secure the right side of the ACM to the bracket on the floor panel transmission tunnel. Tighten the screws to 14 Nm (10 ft. lbs.). 5. Reach through the rearward facing opening below the instrument panel center stack support bracket on the top of the floor panel transmission tunnel to access and reconnect the instrument panel wire harness connector for the ACM to the connector receptacle located on the rearward facing side of the module. Be certain that the latch and the red Connector Position Assurance (CPA) lock on the connector are each fully engaged. 6. On models with an automatic transmission, reinstall the ACM cover onto the instrument panel. (Refer to RESTRAINTS/ACM COVER INSTALLATION). 7. On models with a manual transmission, reinstall the floor console onto the top of the floor panel transmission tunnel. 8. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 372 Air Bag Control Module: Service and Repair Side Impact Airbag Control Module REMOVAL Std CAB WARNING ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Adjust the front seat to its most forward position for easiest access to the lower B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before hirther service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - REMOVAL - STANDARD CAB). Fig. 54 Side Impact Airbag Control Module Remove/Install - Std Cab 4. Remove the four screws that secure the Side Impact Airbag Control Module (SIACM) mounting bracket to the inside of the B-pillar. 5. Reach through the retractor mounting hole in the inner B-pillar to access and disengage the two plastic push-in fasteners that secure the SIACM to the inside of the B-pillar. 6. Pull the SIACM and mounting bracket out through the retractor mounting hole far enough to access and disconnect the body wire harness connector for the SIACM from the module connector receptacle. 7. Remove the SIACM and its mounting bracket from the B-pillar as a unit. Quad CAB WARNING Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 373 - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Adjust the front seat to its most forward position for easiest access to the lower B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before hirther service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - REMOVAL - QUAD CAB). Fig. 55 Side Impact Airbag Control Module Remove/Install - Quad Cab 4. Remove the four screws that secure the Side Impact Airbag Control Module (SIACM) mounting bracket to the inside of the B-pillar. 5. Reach through the retractor mounting hole in the inner B-pillar to access the SIACM and lift it upward far enough to disengage the hook on the mounting bracket from the slot on the inner B-pillar. 6. Pull the SIACM and mounting bracket out through the retractor mounting hole far enough to access and disconnect the body wire harness connector for the SIACM from the module connector receptacle. 7. Remove the SIACM and its mounting bracket from the B-pillar as a unit. INSTALLATION Std CAB WARNING ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > ACM Cover > Page 374 SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Side Impact Airbag Control Module (SIACM) and its mounting bracket to the B-pillar as a unit. 2. Reconnect the body wire harness connector for the SIACM to the module connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the two plastic push-in fasteners that secure the SIACM to the inside of the B-pillar. 4. Loosely install the four screws that secure the SIACM mounting bracket to the base of the B-pillar. 5. Tighten the four screws that secure the SIACM mounting bracket to the B-pillar in the following sequence: upper left, lower right, lower left, upper right. Tighten the screws to 12 Nm (105 in. lbs.). 6. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - INSTALLATION - STANDARD CAB). 7. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Quad CAB WARNING ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE SIDE IMPACT AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SIDE CURTAIN AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. 1. Position the Side Impact Airbag Control Module (SIACM) and its mounting bracket to the B-pillar as a unit. 2. Reconnect the body wire harness connector for the SIACM to the module connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the hook on the SIACM mounting bracket in the slot of the inner B-pillar. 4. Loosely install the four screws that secure the SIACM mounting bracket to the inner B-pillar. 5. Tighten the four screws that secure the SIACM mounting bracket to the B-pillar in the following sequence: upper left, lower right, lower left, upper right. Tighten the screws to 12 Nm (105 in. lbs.). 6. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. (Refer to RESTRAINTS/FRONT OUTBOARD SEAT BELT & RETRACTOR - INSTALLATION - QUAD CAB). 7. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Integrated Power Module (Front View) The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 379 Starter Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 380 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 381 Starter Motor Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 382 Starter Relay: Description and Operation STARTER MOTOR RELAY The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 383 Starter Relay: Testing and Inspection Fig. 12 Type 1 Relay DIAGNOSIS AND TESTING - STARTER MOTOR RELAY The starter relay (Fig. 12) is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. Starter Relay Test 1. Remove starter relay from PDC. 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and Clutch Pedal Position Switch for open or a short. 5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear-shift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to Park/Neutral position switch is OK, refer to Park/Neutral Position Switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 384 Starter Relay: Service and Repair Fig. 13 PDC Location REMOVAL The starter relay is located in the Power Distribution Center (PDC) (Fig. 13). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 392 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 393 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 394 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 395 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 396 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 397 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 398 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 400 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 401 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 402 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 403 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 405 Transmission Control System Relay: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 406 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 407 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Transmission Control System Relay: Connector Views Integrated Power Module (Front View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Integrated Power Module (Rear View) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Transmission Control Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control Transmission Control System Relay: Description and Operation Relay-Transmission Control RELAY-TRANSMISSION CONTROL 45RFE/545RFE DESCRIPTION NOTE: The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. OPERATION When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Relay-Transmission Control > Page 414 Transmission Control System Relay: Description and Operation 47RE Automatic Transmission The Chrysler Corporation does not provide a description of the 47RE Transmission control Relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Transfer Case Control Module C1 Transfer Case Control Module C2 Transfer Case Control Module C3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 419 Control Module: Description and Operation Fig. 7 Transfer Case Control Module (TCCM) Location The Transfer Case Control Module (TCCM) (Fig. 7) is a microprocessor-based assembly, controlling the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the PCI serial bus. Inputs include user selectable 4X4 modes that include 2WD, 4H1, 4L0, and Neutral. The logic and driver circuitry is contained in a molded plastic housing with an embedded heat-sink and is located behind the left side of the lower instrument panel. The Transfer Case Control Module (TCCM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's PCI serial bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TCCM determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TCCM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TCCM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TCCM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal PCI bus traffic being present and the ignition being in the RUN position. - Reduced Power Mode will be entered when the ignition has been powered OFF. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is OFF, or not receive any messages for 5 +/- 0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 +/- 1 seconds. If during Sleep Mode the module detects PCI bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 +/- 1 seconds. SHIFT REQUIREMENTS If the TCCM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TCCM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 420 Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TCCM. - Proper transmit/receive messages are occurring on the PCI bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: Front and rear wheel speed are within 21 km/hr (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds +/- 100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the PCI bus. - Clutch signal is recognized for 500 msec +/- 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TCCM. A shift into transfer case Neutral will be allowed only if all of the following conditions are met: Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds +/- 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position, engine OFF. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: Front and rear wheel speed are within 21 km/hr (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds +/- 100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the PCI bus. - Vehicle speed is less than or equal to 4.8 km/hr (3 miles per hour). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TCCM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TCCM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TCCM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TCCM strategy for handling blocked shifts will be described later. The process the TCCM performs for the various shifts will be described first. Range And Mode Shifts The process for performing all the range and mode shifts are the same. The following steps describe the process. Allow time for Selector Switch debounce; 250 msec +/- 50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second +/- 100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec +/- 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds +/- 100 msec. per 'D' channel. The TCCM waits for 2.0 seconds +/- 50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/ AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 421 Shift Out Of Neutral Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second +/- 100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec +/- 50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The TCCM waits for 2.0 seconds +/- 50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second +/- 100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the section on Blocked Shift Strategy BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TCCM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TCCM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TCCM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TCCM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TCCM stores the position in memory as the transfer case's intended position. The TCCM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TCCM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TCCM will wait for 2.0 seconds +/- 50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 422 following conditions: Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second +/- 100 msec calibrated window of time. After 5 minutes +/- 100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2000-2002, do not use a heated window relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 427 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2000-2002, do not use a heated window relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2000-2002, do not use a heated window relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 431 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2000-2002, do not use a heated window relay. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation Wiper Control Module: Description and Operation Fig. 21 Wiper Module WIPER MODULE The wiper motor bracket is secured with two screws below the wiper motor through two rubber insulators to the bottom of the cowl plenum panel beneath the cowl plenum cover/grille panel. Two screws secure the top of the wiper module bracket to the cowl plenum panel through rubber insulators located on the outboard end of each pivot bracket. The ends of the wiper pivot shafts that protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: Bracket - The wiper module bracket consists of a long tubular steel main member that has a die cast pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage - Two stamped steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm of its respective pivot. The right side drive link sleeve- type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has two rubber insulated mounting ears at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 436 The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper ON/OFF and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 437 Wiper Control Module: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. (Refer to WIPERS/WASHERS/ WIPER ARM REMOVAL). 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel from over the cowl plenum. Fig. 22 Wiper Module Remove/Install 5. Disconnect the left headlamp and dash wire harness connector for the wiper motor from the motor pigtail wire connector. 6. Remove the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. 7. Remove the two screws that secure the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION 1. Position the wiper module into the cowl plenum as a unit. 2. Install the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 7 Nm (60 in. lbs.). 3. Install and tighten the screws that secure the wiper module to the bottom of the cowl plenum panel. Tighten the screw on the passenger side, followed by the screw on the driver side. Tighten the screws to 7 Nm (60 in. lbs.). 4. Reconnect the left headlamp and dash wire harness connector for the wiper motor to the motor pigtail wire connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Description and Operation > Page 438 5. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms onto the wiper pivots. (Refer to WIPERS/WASHERS/ WIPER ARMS - INSTALLATION). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Component Locations Wiper Relay: Component Locations Integrated Power Module (Front View) The wiper ON/OFF relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 443 Wiper Relay: Diagrams 8w-10-2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 444 8w-10-3 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 445 Wiper High/Low Relay Wiper On/Off Relay Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 446 Wiper Relay: Service Precautions Fig. 19 ISO Micro Relay The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Relay-Wiper High/Low Wiper Relay: Description and Operation Relay-Wiper High/Low Fig. 18 ISO Micro Relay WIPER HIGH/LOW RELAY The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper high/low relay. The relay switches power between the low speed and high speed brush of the wiper motor. The wiper high/low relay is then actuated through the low side control circuit. This circuit is electronically controlled and continuously monitored for malfunctions. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper ON/OFF relay at all times through the wiper ON/OFF relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the ON or Accessory positions from a fuse in the Integrated Power Module (IPM) through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accurate means to diagnose the wiper high/low relay, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the wiper high/low Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Relay-Wiper High/Low > Page 449 relay operation requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Relay-Wiper High/Low > Page 450 Wiper Relay: Description and Operation Relay-Wiper On/Off Fig. 23 ISO Micro Relay WIPER ON/OFF RELAY The wiper switch is a direct input to the instrument cluster. The instrument cluster sends a PCI bus request to the FCM to actuate the wiper ON/OFF relay. The wiper ON/OFF relay is then actuated through the low side control circuit. This relay switches power to the wiper high/low relay. This circuit is electronically controlled and continuously monitored for malfunctions. The wiper ON/OFF relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery The wiper ON/OFF relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base. The wiper ON/OFF relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The wiper ON/OFF relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper ON/OFF relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper ON/OFF relay include: Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper ON/OFF relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper ON/OFF relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper ON/OFF relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper ON/OFF relay out- put circuit whenever the relay is de-energized. The wiper ON/OFF relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic message inputs to or outputs from Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > Relay-Wiper High/Low > Page 451 the instrument cluster and the FCM that control the operation of the wiper ON/OFF relay. The most reliable, efficient, and accurate means to diagnose the wiper ON/OFF relay, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the wiper ON/OFF relay operation requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Test Wiper Relay: Testing and Inspection Wiper High/Low Relay Test Fig. 19 ISO Micro Relay The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the wiper high/low relay from the IPM. (Refer to WIPERS/WASHERS/ WIPER HIGH/LOW RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Test > Page 454 Wiper Relay: Testing and Inspection Wiper On/Off Relay Test Fig. 24 ISO Micro Relay The wiper ON/OFF relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the wiper ON/OFF relay from the IPM. (Refer to WIPERS/WASHERS/ WIPER ON/OFF RELAY - REMOVAL). 2. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 8 ohms. If OK, go to Step 4. If not OK, replace the faulty relay. 4. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, reinstall the relay and use a DRB III scan tool to perform further testing. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Wiper High/Low Relay Replacement Wiper Relay: Service and Repair Wiper High/Low Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 20 Integrated Power Module 2. Remove the cover from the Integrated Power Module (IPM). 3. Remove the wiper high/low relay by grasping it firmly and pulling it straight out from the receptacle in the IPM. INSTALLATION 1. Position the wiper high/low relay to the proper receptacle in the Integrated Power Module (IPM). 2. Align the wiper high/low relay terminals with the terminal cavities in the IPM receptacle. 3. Push firmly and evenly on the top of the wiper high/low relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 4. Reinstall the cover onto the IPM. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Service and Repair > Wiper High/Low Relay Replacement > Page 457 Wiper Relay: Service and Repair Wiper on/Off Relay Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Fig. 25 Integrated Power Module 2. Remove the cover from the Integrated Power Module (IPM). 3. Remove the wiper ON/OFF relay by grasping it firmly and pulling it straight out from the receptacle in the IPM. INSTALLATION 1. Position the wiper ON/OFF relay to the proper receptacle in the Integrated Power Module (IPM). 2. Align the wiper ON/OFF relay terminals with the terminal cavities in the IPM receptacle. 3. Push firmly and evenly on the top of the wiper ON/OFF relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. 4. Reinstall the cover onto the IPM. 5. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 463 Lock Cylinder Switch: Diagrams Cylinder Lock Switch Driver (Premium) Cylinder Lock Switch-Passenger (Premium) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Diagrams Adjustable Pedal Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Remote Radio Switch - Left Remote Radio Switch - Right Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 470 Remote Switch: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 471 Remote Switch: Description and Operation Fig. 12 Remote Radio Switch Operational View A remote radio control switch option is available on some models. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Integrated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a DRB III scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the features and control functions for each of the remote radio switches, refer to the owner's manual. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 472 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of the DRB III diagnostic tool. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Fig. 13 Remote Radio Switches 1. Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) from the steering wheel (Refer to AUDIO/REMOTE SWITCHES - REMOVAL). Remote Radio Switch Test Table 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch. 3. Reconnect the battery negative cable. Turn the ignition switch to the ON position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 4. If not OK, repair the open or shorted radio control mux circuit to the Integrated Power Module (IPM) as required. 4. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the IPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 473 and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted remote radio switch ground circuit to the IPM as required. 5. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the IPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the IPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 474 Remote Switch: Service and Repair REMOVAL WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the vehicle (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). 3. Remove the speed control switches (Refer to SPEED CONTROL/SWITCH - REMOVAL). 4. Unplug the wire harness connector from the remote radio switch(es). Fig. 14 Remote Switches 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install remote radio switch to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (Refer to SPEED CONTROL/SWITCH INSTALLATION). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Description and Operation Road Temperature Sensor: Description and Operation AMBIENT TEMP SENSOR Ambient air temperature is monitored by the overhead console through ambient temperature messages received from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) J1850 data bus circuit. The FCM receives a hard wired input from the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the headlamp mounting module grille opening, behind the radiator grille and in front of the engine compartment. Refer to Front Control Module in Electronic Control Modules. For complete circuit diagrams, refer to the appropriate wiring information. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the Front Control Module. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Front Control Module. Based upon the resistance in the sensor, the Front Control Module senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. The Front Control Module then sends the proper ambient temperature messages to the EVIC, CMTC over the PCI J1850 data bus. The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the Front Control Module, the Programmable Communications Interface (PCI) data bus, and a portion of the Electronics module. If any portion of the ambient temperature sensor circuit fails, the Front Control Module will self-diagnose the circuit. The ambient temperature sensor circuit can also be diagnosed by referring to Diagnosis and Testing - Ambient Temperature Sensor, and Diagnosis and Testing - Ambient Temperature Sensor Circuit. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, refer to Diagnosis and Testing - Overhead Console in this group. For complete circuit diagrams, refer to the appropriate wiring information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > Ambient Temperature Sensor Test Road Temperature Sensor: Testing and Inspection Ambient Temperature Sensor Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At -40 °C (-40 °F), the sensor resistance is 336 kilohms. At 55 °C (140 °F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Diagnosis and Testing - Ambient Temperature Sensor Circuit in this group. If not OK, replace the faulty ambient temperature sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > Ambient Temperature Sensor Test > Page 480 Road Temperature Sensor: Testing and Inspection Ambient Temperature Sensor Circuit Test 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the Front Control Module wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the Front Control Module wire harness connector. There should be continuity If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the Front Control Module wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the Front Control Module wire harness connector and a good ground. There should be no continuity. If OK, refer to Diagnosis and Testing - Overhead Console in this group. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Testing and Inspection > Page 481 Road Temperature Sensor: Service and Repair AMBIENT TEMPERATURE SENSOR REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Diagrams Adjustable Pedal Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Door Lock Switch Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 489 Power Door Lock Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DOOR MODULE - DIAGNOSIS AND TESTING). If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin- out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. Fig.5 Powr Lock Switch Connector Receptable Power Lock Switch Test Table 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 490 Power Door Lock Switch: Service and Repair REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module. (Refer to POWER LOCKS/DOOR MODULE - REMOVAL). 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, gently pry the switch bezel from the door panel. 3. Disconnect the electrical harness connector from the switch. 4. Remove switch from bezel. INSTALLATION 1. Insert switch to bezel. 2. Connect electrical harness connector to switch. 3. Press bezel into place on door trim panel. 4. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the Driver Door Module. (Refer to POWER LOCKS/DOOR MODULE - DIAGNOSIS AND TESTING). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 494 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE - REMOVAL). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Switch: Locations LUMBAR CONTROL SWITCH The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 498 Power Seat Switch: Diagrams Passenger Lumbar Switch Power Seat Switch - Driver Power Seat Switch - Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 499 Power Seat Switch: Description and Operation Fig. 1 DR Power Seat Switch DRIVER SEAT SWITCH The power seat on this model can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch on this model has an additional switch knob for adjusting the power lumbar support. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or faulty, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 500 Fig. 1 DR Power Seat Switch PASSENGER SEAT SWITCH The power seat on this model can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch on this model has an additional switch knob for adjusting the power lumbar support. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or faulty the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. LUMBAR CONTROL SWITCH The power lumbar seat option includes an electrically operated lumbar support mechanism. A single two-way momentary power lumbar switch is integral with the power seat switches. The power lumbar switch is secured to the back of the seat cushion side shield with screws, and the switch paddle protrudes through a hole to the outside of the shield. The switch paddle is located in a shallow depression molded into the outer surface of the seat cushion side shield that helps to shroud it from unintentional actuation when entering or leaving the vehicle. The power lumbar switches cannot be adjusted or repaired and, if faulty or damaged, the seat switch assembly must be replaced. When the power lumbar switch paddle is actuated, a battery feed and a ground path are applied through the switch contacts to the power lumbar adjuster motor. The motor operates to move the lumbar adjuster through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the motor to run in the opposite direction. The power lumbar switch should not be held applied in either direction after the adjuster has reached its travel limit. The power lumbar adjuster motor contains a self-resetting circuit breaker to protect it from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Switch Test Power Seat Switch: Testing and Inspection Driver Seat Switch Test For circuit descriptions and diagrams, refer to Wiring. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Fig. 2 Testing Driver Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, refer to Power Seat Track Diagnosis and Testing in this group. If not OK, replace the faulty power seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Seat Switch Test > Page 503 Power Seat Switch: Testing and Inspection Passenger Seat Switch Test For circuit descriptions and diagrams, refer to Wiring. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Fig. 5 Testing Passenger Power Seat Switch 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, refer to Power Seat Track Diagnosis and Testing in this group. If not OK, replace the faulty power seat switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Seat Switch Replacement Power Seat Switch: Service and Repair Driver Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to the Body section for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. Power Seat Switch Remove/Install - Typical 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and install the screws that secure the power seat switch to seat cushion side shield. 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. Refer to the Body section of the service manual for the procedure. 4. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Seat Switch Replacement > Page 506 Power Seat Switch: Service and Repair Passenger Seat Switch Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. Refer to the Body section for the procedure. 3. Pull the switch bezel or side shield unit out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. Power Seat Switch Remove/Install - Typical 4. Remove the screws that secure the power seat switch. INSTALLATION 1. Position the power seat switch on the seat cushion side shield and install the screws that secure the power seat switch to seat cushion side shield. 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. Refer to the Body section for the procedure. 4. If equipped, install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat. 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver Seat Switch Replacement > Page 507 Power Seat Switch: Service and Repair Lumbar Control Switch Replacement REMOVAL The power lumbar switch is integral with the other power seat switches. Refer to the appropriate driver or passenger power front seat switch removal and/or installation procedure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor One temperature sensor is used for each seat. This temperature sensor is located in the seat cushion heating element on all models. The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if defective. The heated seat cushion element must be replaced if the temperature sensor is defective. The temperature sensor is a NTC thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 511 Seat Heater Sensor: Testing and Inspection NOTE: ANY RESISTANCE VALUES (OHMS) GIVEN IN THE FOLLOWING TEXT ARE SUPPLIED USING THE AUTOMATIC RANGE GENERATED BY A FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE OF MEASURING DEVICE IS USED THE VALUES GENERATED MAY NOT BE THE SAME AS THE RESULTS SHOWN HERE, OR MAY HAVE TO BE CONVERTED TO THE RANGE USED HERE. 1. Position the appropriate seat in the full forward position. 2. Make certain the ignition switch is in the OFF position. 3. Disconnect the 4-way heated seat wire harness connector from the seat cushion frame. Using an ohmmeter, check the resistance between the heated seat sensor input circuit cavity and the heated seat sensor feed circuit cavity in the 4-way heated seat wire harness connector. The heated seat sensor resistance should be between 1 kilohm and 100 kilohms. If OK, go to Step 4. If not OK, replace the faulty seat cushion heating element assembly 4. Test the seat wire harness between the heated seat module connector and the 4-way heated seat wire harness connector for shorted or open circuits. If OK, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules, for the proper heated seat module diagnosis and testing procedures. If not OK, repair the shorted or open heated seat wire harness as required. For complete circuit diagrams, refer to Wiring Diagrams. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 512 Seat Heater Sensor: Service and Repair REMOVAL 1. For heated seat sensor replacement procedure (Refer to HEATED SEATS/HEATED SEAT ELEMENT - REMOVAL). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Heated Seat Cushion - Driver Heated Seat Switch - Passenger Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 516 Seat Heater Switch: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 517 Seat Heater Switch: Description and Operation DRIVER HEATED SEAT SWITCH The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The momentary, bi-directional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module on the mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are ON. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater OFF. The heated seat module will then turn the heated seat elements for that seat OFF. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the ON position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps ON and OFF. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned ON, and their illumination intensity is controlled by the panel lamps dimmer switch. PASSENGER HEATED SEAT SWITCH The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The two heated seat switches are identical in appearance and construction, except for the location of a keyway in the single connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical. The momentary, bi-directional rocker-type heated seat switch provides a resistor-multiplexed signal to the heated seat module on the mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a preferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on. The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced. The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard- wired resistor multiplexed voltage request signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a second time to the same position as the currently selected state, the heated seat module interprets the second input as a request to turn the seat heater off. The heated seat module will then turn the heated seat elements for that seat off. The indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by a separate (high or low/driver or passenger) indicator lamp driver circuit by the heated seat module. The heated seat module control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator to indicate monitored heated seat system faults by flashing the indicator lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is connected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned ON, and their illumination intensity is controlled by the panel lamps dimmer switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test Seat Heater Switch: Testing and Inspection Driver Heated Seat Switch Test Refer to Wiring Diagrams for the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, refer to Instrument Cluster for the proper cluster illumination lamps diagnosis and testing procedures. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the instrument panel wire harness connector for the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps ON with the headlamp switch. Rotate the panel lamps dimmer thumbwheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer switch signal circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, replace the faulty heated seat switch. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the Integrated Power Module fuse as required. Fig. 1 Heated Seat Switches 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. NOTE: ANY RESISTANCE VALUES (OHMS ) GIVEN IN THE FOLLOWING TEXT ARE SUPPLIED USING THE AUTOMATIC RANGE GENERATED BY A FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE OF MEASURING DEVICE IS USED THE VALUES GENERATED MAY NOT BE THE SAME AS THE RESULTS SHOWN HERE, OR MAY HAVE TO BE CONVERTED TO THE RANGE USED HERE. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 520 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 521 Seat Heater Switch: Testing and Inspection Passenger Heated Seat Switch Test Refer to Wiring Diagrams for the location of complete heated seat system wiring diagrams. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the problem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, refer to Instrument Cluster for the proper cluster illumination lamps diagnosis and testing procedures. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat elements do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned OFF, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. 2. Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the instrument panel wire harness connector for the heated seat switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required. 3. Reconnect the battery negative cable. Turn the park lamps ON with the headlamp switch. Rotate the panel lamps dimmer thumbwheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer switch signal circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, replace the faulty heated seat switch. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required. 4. Turn the ignition switch to the ON position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel wire harness connector for the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit to the Integrated Power Module fuse as required. Fig. 8 Heated Seat Switches 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart. If OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. NOTE: ANY RESISTANCE VALUES (OHMS ) GIVEN IN THE FOLLOWING TEXT ARE SUPPLIED USING THE AUTOMATIC RANGE GENERATED BY A FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE OF MEASURING DEVICE IS USED THE VALUES GENERATED MAY NOT BE THE SAME AS THE RESULTS SHOWN HERE, OR MAY HAVE TO BE CONVERTED TO THE RANGE USED HERE. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Testing and Inspection > Driver Heated Seat Switch Test > Page 522 6. Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, refer to Heated Seat Module in Electronic Control Modules for the location of the proper heated seat module diagnosis and testing procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement Seat Heater Switch: Service and Repair Driver Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel. 3. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 4. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 5. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. Note that the driver side and passenger side switches are identical in appearance except for the keyway in the connector receptacle on the backs of the switches. The driver side switch has the keyway located near the bottom of the connector receptacle and should be installed in the left mounting hole of the heated seat switch bezel. The passenger side switch has the keyway located near the top of the connector receptacle and should be installed in the right mounting hole of the heated seat switch bezel. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Driver Heated Seat Switch Replacement > Page 525 Seat Heater Switch: Service and Repair Passenger Heated Seat Switch Replacement REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel. 3. Remove the screws that secure the heated seat switch bezel to the instrument panel center bezel. 4. Remove the heated seat switch bezel and both switches from the instrument panel as a unit. 5. From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel. INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. Note that the driver side and passenger side switches are identical in appearance except for the keyway in the connector receptacle on the backs of the switches. The driver side switch has the keyway located near the bottom of the connector receptacle and should be installed in the left mounting hole of the heated seat switch bezel. The passenger side switch has the keyway located near the top of the connector receptacle and should be installed in the right mounting hole of the heated seat switch bezel. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel. 2. Position the heated seat switch bezel to the instrument panel center bezel and install the retaining screws. 3. Install the center bezel on the instrument panel. 4. Connect the negative battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 530 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Service and Repair Parking Brake Release Switch: Service and Repair RELEASE HANDLE REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel. 3. Disengage the park brake release linkage rod end from the park brake mechanism. 4. Lift the park brake release handle to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle. 5. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. 6. Lift the park brake release handle to access the handle mounting bracket. 7. Using a trim stick or another suitable wide flat-bladed tool, gently pry each of the park brake release handle mounting bracket latch tabs away from the retaining notches in the instrument panel receptacle. 8. With both of the park brake release handle mounting bracket latches released, slide the handle and bracket assembly down and out of the instrument panel receptacle. INSTALLATION 1. Position the park brake release handle to the instrument panel. 2. Slide the handle and bracket assembly up into the instrument panel receptacle until both of the park brake release handle mounting bracket latches are engaged with the notches in the instrument panel receptacle. 3. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to engage the park brake release linkage rod end with the lever on the back of the park brake release handle. 4. Lift the park brake release handle to access and snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle over the linkage rod. 5. Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end to the park brake mechanism. 6. Snap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel over the linkage rod. 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Wheel Speed Sensors Front Sensor Bolt 190 inch lbs. Wheel Speed Sensors Bracket To Knuckle 60 inch lbs. Wheel Speed Sensors Rear Sensor Stud 200 inch lbs. Rear Wheel Speed Sensor Mounting Bolt 200 inch lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 539 Wheel Speed Sensor: Connector Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 540 Wheel Speed Sensor: Diagrams Wheel Speed Sensor - Left Front (ABS) Wheel Speed Sensor - Rear (ABS) Wheel Speed Sensor - Right Front (ABS) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 541 Wheel Speed Sensor: Description and Operation FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the CAB. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings. This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated. Each AC signal (positive to negative signal or sinewave) is interpreted by the CAB. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The CAB continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/ tone wheel rotates, the stronger the signal will be - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The rear WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 - 0.050 inch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 542 The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear Wheel Anti Lock Wheel Speed Sensor: Testing and Inspection Rear Wheel Anti Lock REAR WHEEL SPEED SENSOR DIAGNOSIS AND TESTING - REAR WHEEL ANTI LOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or DRB III scan tool is used to diagnose the RWAL system. REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud from the sensor and shield. 4. Remove the sensor and shield from the differential housing. 5. Disconnect the sensor wire harness and remove the sensor. INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor in the differential housing. 4. Install the sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear Wheel Anti Lock > Page 545 Wheel Speed Sensor: Testing and Inspection Rear Wheel Speed Sensor TONE WHEEL DIAGNOSIS AND TESTING - REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: The MDS or ORB III scan tool is used to diagnose the Antilock Brake system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Page 546 Wheel Speed Sensor: Service and Repair FRONT WHEEL SPEED SENSOR REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt from the hub. 3. Remove the wheel speed sensor from the hub. 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor to the hub. 3. Install the wheel speed sensor mounting bolt to the hub. Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 552 Engine Coolant Temperature Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 553 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCM (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 554 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE SENSOR REMOVAL 3.7L The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor from the intake manifold. 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 555 The Engine Coolant Temperature (ECT) sensor is located near the front of the intake manifold. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the ECT sensor. 3. Remove the sensor from the intake manifold. 5.9L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the sensor. 3. Engines with air conditioning: When removing the connector from the sensor, do not pull directly on the wiring harness. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove the sensor from the intake manifold. INSTALLATION 3.7L Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 556 1. Apply thread sealant to the sensor threads. 2. Install the sensor to the engine. 3. Tighten the sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect the electrical connector to the sensor. 5. Replace any lost engine coolant. 4.7L 1. Apply thread sealant to the sensor threads. 2. Install the sensor to the engine. 3. Tighten the sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect the electrical connector to the sensor. 5. Replace any lost engine coolant. 5.9L 1. Apply thread sealant to the sensor threads. 2. Install the sensor to the engine. 3. Tighten the sensor to 6 - 8 Nm (55 - 75 inch lbs.) torque. 4. Connect the electrical connector to the sensor. The sensor connector is symmetrical (not indexed). It can be connected to the sensor in either direction. 5. Refill the cooling system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications Cruise Control Switch: Specifications Speed Control Switch Mounting Screws 1.7 Nm 15 In. Lbs Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 561 Cruise Control Switch: Diagrams Speed Control Switch - Left Speed Control Switch - Right Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 562 Cruise Control Switch: Service Precautions WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE(S) FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 563 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal. - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate with- out disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch, which powers the speed control servo. Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sensor point (open circuit). If a switch with no resistor is closed, the PCM will measure 0 volts (grounded circuit). Now, if a resistor is added to a switch, then the PCM will measure some voltage proportional to the size of the resistor. By adding a different resistor to each switch, the PCM will see a different voltage depending on which switch is pushed. Another resistor has been added to the 'at rest circuit' causing the PCM to never see 5 volts. This was done for diagnostic purposes. If the switch circuit should open (bad connection), then the PCM will see the 5 volts and know the circuit is bad. The PCM will then set an open circuit fault. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Specifications > Page 564 Cruise Control Switch: Service and Repair Fig. 8 Speed Control Switches REMOVAL 1. Remove switch mounting screw. 2. Pull switch from steering wheel. 3. Unplug electrical connector and remove switch. INSTALLATION 1. Plug electrical connector into switch. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 570 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 571 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 572 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 573 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 574 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 575 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 576 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 577 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 578 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 579 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 580 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 581 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 582 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Oil Pressure Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 584 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 585 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 586 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 587 Engine Oil Pressure Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor C205 C205 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 592 Ambient Temperature Sensor / Switch HVAC: Description and Operation AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the Front Control Module (FCM) and displayed by the Compass/mini-trip Computer /Electronic Vehicle Information Center (CMTC/EVIC). The FCM receives a hardwire input from the Ambient Temperature Sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the Programmable Communication Interface (Vehicle Communication Bus) (PCI) Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the CMTC/EVIC display indicates 54° C (130° F) or the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate a SHORT circuit condition. If the CMTC/EVIC display indicates -40° C (-40 ° F) or the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the Sensor Test. Test the ATS circuits using the diagnostics at Body Control System. If the EVIC passes the self test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the EVIC temperature display is inoperative or incorrect, replace the FCM. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 593 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions Blower Motor Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 597 Blower Motor Switch: Description and Operation The A/C Heater blower motor is controlled by a four position rotary-type blower motor switch, mounted in the A/C Heater control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned OFF by selecting the OFF position on the blower motor switch. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C Heater control unit must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 598 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. Remove the A/C Heater control from the instrument panel. Check for continuity between the ground circuit cavity of the A/C Heater control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the A/C Heater control wire harness connector unplugged, place the A/C Heater mode control switch knob in any position except the OFF position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the A/C Heater control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the A/C Heater control connector and the blower motor resistor as required. If not OK, replace the faulty A/C Heater control unit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service Precautions > Page 599 Blower Motor Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C Heater control unit must be replaced. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. The blower motor switch cannot be repaired and, if faulty or damaged the entire A/C heater control unit must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 603 Evaporator Temperature Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condensor in the front corner of the engine compartment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 607 A/C Pressure Transducer Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 608 Refrigerant Pressure Sensor / Switch: Description and Operation A/C PRESSURE TRANSDUCER The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant discharge line between the compressor and the condensor in the front corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader-type fitting on the liquid line. A rubber O-ring seals the connection between the transducer and the discharge line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a take out and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it musty be replaced. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10 °C due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 609 Refrigerant Pressure Sensor / Switch: Testing and Inspection A/C PRESSURE TRANSDUCER A/C Pressure Transducer Voltage The A/C pressure transducer is tested using a DRB III scan tool. Refer to the appropriate diagnostic information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM). The PCM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage table for the possible condition indicated by the transducer voltage readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 610 Refrigerant Pressure Sensor / Switch: Service and Repair A/C PRESSURE TRANSDUCER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the wire harness connector for the A/C pressure transducer from the transducer connector receptacle. 3. Using an open end wrench, unscrew the A/C pressure transducer from the fitting on the discharge line between the compressor and the condenser. 4. Remove the seal from the A/C pressure transducer fitting and discard. INSTALLATION 1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. 2. Using an open end wrench, install and tighten the A/C pressure transducer onto the fitting on the discharge line between the compressor and the condenser. 3. Reconnect the wire harness connector for the A/C pressure transducer to the transducer connector receptacle. 4. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 618 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 619 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 620 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 621 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 622 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 623 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 624 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 625 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 626 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 627 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 628 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 629 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 630 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 631 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 632 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 633 Door Switch: Connector Views Door Ajar Switch Driver (Base) Door Ajar Switch - Left Rear (Base) Door Ajar Switch - Passenger (Base) Door Ajar Switch - Right Rear (Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 634 Door Lock Motor/Ajar Switch Driver (Except Base) Door Lock Motor/Ajar Switch - Left Rear (Except Base) Door Lock Motor/Ajar Switch - Passenger (Except Base) Door Lock Motor/Ajar Switch - Right Rear (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 635 Door Ajar System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 636 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Instrument Cluster when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Refer to the Body section under Doors for the removal and installation procedure. The door ajar switches close a path to ground for the Instrument Cluster when a door is opened. The passenger front door is connected in a parallel-series circuit between ground and the Instrument Cluster, while the driver side front door ajar switch is connected in series between ground and the Instrument Cluster to provide a unique input. The Instrument Cluster reads the switch status, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Refer to the Body section under Doors for the Removal and Installation procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Fuel Gauge Sender: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Fig. 4 Location - Fuel Gauge Sending Unit The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (Fig. 4). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 642 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 643 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 644 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 645 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 646 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 647 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 648 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 649 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 650 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 651 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 652 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 653 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 654 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 655 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 656 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 657 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 658 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 659 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 660 Fuel Gauge Sender: Testing and Inspection FUEL LEVEL SENDING UNIT The fuel level sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. Refer to Instrument Panel and Gauges for Fuel Gauge testing. To test the gauge sending unit only, it must be removed from vehicle. The unit is a part of the fuel pump module. Refer to Fuel Pump Module Removal/Installation for procedures. Measure the resistance across the sending unit terminals. With float in up position, resistance should be 20 ohms (± 6 ohms). With float in down position, resistance should be 220 ohms (± 6 ohms). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 661 Fuel Gauge Sender: Service and Repair REMOVAL Fig. 4 Location - Fuel Gauge Sending Unit The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (Fig. 4). 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. Fig. 5 Fuel Gauge Sending Unit - R/I 2. To remove sending unit from pump module, lift on plastic locking tab (Fig. 5) while sliding sending unit tracks. 3. Disconnect 4-wire electrical connector (Fig. 4) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 662 INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY IN IGNITION SWITCH The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition lock cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition lock cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation > Page 666 Key Reminder Switch: Testing and Inspection DIAGNOSIS, TESTING AND REPAIR - IGNITION SWITCH If the key removal effort is excessive on a vehicle with a automatic transmission first adjust the shift linkage. If the ignition switch effort is excessive remove the ignition key cylinder from the steering column. Check the turning effort of the key cylinder. If the ignition key cylinder effort is excessive replace the key cylinder. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 672 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 673 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 674 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 675 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 676 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 677 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 678 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 679 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 680 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 681 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 683 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 684 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 686 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 687 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 692 Brake Lamp Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 693 Brake Light Switch: Description and Operation The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel. CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed. The brake lamp switch is monitored by the Instrument Cluster and used for the brake lamp, speed control brake sensor circuits and Electronic Brake Distribution (EBD). The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits are closed until the plunger is depressed. When the instrument cluster notices the brake lamp switch transition, it transmits a brake applied/released message on the bus. The Front Control Module (FCM) will then illuminate or turn off the brake lamps. When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo. Vehicles equipped with the speed control option use a dual function brake lamp switch. The PCM monitors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two normally closed (brakes disengaged). The PCM sends a 12 volt signal to one of the normally closed contacts in the brake switch, which is returned to the PCM as a brake switch state signal. With the contacts closed, the 12 volt signal is pulled to ground causing the signal to go low. The low voltage signal, monitored by the PCM, indicates that the brakes are not applied. When the brakes are applied, the contacts open, causing the PCM's output brake signal to go high, disengaging the speed control, cutting off PCM power to the speed control solenoids. The second set of normally closed contacts supplies 12 volts from the PCM any time speed control is turned on. Through the brake switch, current is routed to the speed control servo solenoids. The speed control solenoids (vacuum, vent and dump) are provided this current any time the speed control is ON and the brakes are disengaged. When the driver applies the brakes, the contacts open and current is interrupted to the solenoids. The normally open contacts are fed battery voltage. When the brakes are applied, battery voltage is supplied to the brake lamps. The brake lamp switch can only be adjusted once. That is at the initial installation of the switch. If the switch is not adjusted properly or has been removed, a new switch must be installed and adjusted. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 694 Brake Light Switch: Testing and Inspection Fig.1 Brake Lamp Switch Terminal Identification The brake lamp switch can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals. Switch Circuit Identification Terminals 1 and 2: brake lamp circuit - Terminals 3 and 4: RWAL/ABS module and Powertrain Control Module (PCM) circuit - Terminals 5 and 6: speed control circuit Switch Continuity Test NOTE: Disconnect switch harness before testing switch continuity. With switch plunger extended, attach test leads to pins 1 and 2. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 3 and 4. Replace switch if meter indicates no continuity. With switch plunger retracted, attach test leads to pins 5 and 6. Replace switch if meter indicates no continuity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 695 Brake Light Switch: Service and Repair Fig. 3 Brake Lamp Switch & Bracket REMOVAL 1. Disconnect the switch harness. 2. Press and hold the brake pedal in applied position. 3. Rotate the switch counterclockwise about 300 to align the switch lock tab with the notch in bracket. 4. Pull the switch rearward out of the mounting bracket and release the brake pedal. INSTALLATION 1. Press and hold the brake pedal down. 2. Align the tab on the new switch with the notch in the switch bracket. Insert the switch in the bracket and turn it clockwise about 30 ° to lock it in place. 3. Connect the harness wires to the switch. 4. Release the brake pedal. 5. Move the release lever on the switch parallel with the connector to engage the switch plunger. The switch is now adjusted and can not be adjusted again. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications Combination Switch: Specifications Steering Column Multi-function Switch Screws 9 ft. lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 699 Combination Switch: Description and Operation TURN SIGNAL SYSTEM The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned off by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either camlobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 700 Combination Switch: Testing and Inspection To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. Multi-Function Switch Tests 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Specifications > Page 701 Combination Switch: Service and Repair REMOVAL WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. 3. Disconnect the wire connector from the back of the multi-function switch. Fig.15 Multifunction Switch 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clockspring to the multifunction switch. INSTALLATION 1. Install the clockspring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 706 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 707 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 709 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 710 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 715 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Door Switch: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 720 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 721 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 722 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 723 Door Switch: Connector Views Door Ajar Switch Driver (Base) Door Ajar Switch - Left Rear (Base) Door Ajar Switch - Passenger (Base) Door Ajar Switch - Right Rear (Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Door Lock Motor/Ajar Switch Driver (Except Base) Door Lock Motor/Ajar Switch - Left Rear (Except Base) Door Lock Motor/Ajar Switch - Passenger (Except Base) Door Lock Motor/Ajar Switch - Right Rear (Except Base) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Door Ajar System Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 726 Door Switch: Description and Operation DOOR AJAR SWITCH The door ajar switches are integral to the door latches on each door The switches close a path to ground for the Instrument Cluster when a door is opened. The door ajar switches cannot be repaired and, if faulty or damaged, the door latch unit must be replaced. Refer to the Body section under Doors for the removal and installation procedure. The door ajar switches close a path to ground for the Instrument Cluster when a door is opened. The passenger front door is connected in a parallel-series circuit between ground and the Instrument Cluster, while the driver side front door ajar switch is connected in series between ground and the Instrument Cluster to provide a unique input. The Instrument Cluster reads the switch status, then sends the proper switch status messages to other electronic modules over the Programmable Communications Interface (PCI) data bus network. The door ajar switches can be diagnosed using conventional diagnostic tools and methods. Refer to the Body section under Doors for the Removal and Installation procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams Glove Box Lamp And Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Diagrams > Page 730 Glove Box Lamp Switch: Service and Repair GLOVE BOX LAMP/SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable 2. Remove the glove box from the instrument panel. Fig. 3 Glove Box Lamp And Switch Remove/Install 3. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch. 4. Disconnect the instrument panel wire harness connector from the connector receptacle on the back of the glove box lamp and switch unit. 5. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 6. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 7. Remove the glove box lamp and switch unit from the instrument panel. INSTALLATION 1. Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to feed the instrument panel wire harness connectors out through the hole in the glove box lamp and switch housing mounting bracket. 2. Position the glove box lamp and switch unit to the instrument panel. 3. Reconnect the instrument panel wire harness connector to the connector receptacle on the back of the glove box lamp and switch unit. 4. Push the glove box lamp and switch unit into the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 5. Install the glove box onto the instrument panel. 6. Close the glove box 7. Reconnect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 734 Hazard Warning Switch: Service Precautions WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 735 Hazard Warning Switch: Description and Operation HAZARD SWITCH The hazard switch is activated by a push button located in the multifunction switch on the top of the steering column between the steering wheel and instrument cluster. The hazard warning system allows the vehicle operator to provide other vehicle operators in the near proximity an optical indication that the vehicle is disabled or an obstacle to traffic flow. The hazard warning system has battery voltage at all times, regardless of ignition position. The instrument cluster monitors the multiplexed multifunction switch operation. When the hazard warning switch is activated, the instrument cluster will send a J1850 bus message to the Front Control Module (FCM), then activate the two turn signal indicators and audible click in the instrument cluster. The FCM will then activate the necessary relays in the Power Distribution Center (PDC) to begin flashing both the front and rear turn signal indicator lamps. MULTI-FUNCTION SWITCH Turn Signal System The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned OFF by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 736 Hazard Warning Switch: Testing and Inspection MULTI FUNCTION SWITCH Multi-Function Switch Tests To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 737 Hazard Warning Switch: Service and Repair MULTI FUNCTION SWITCH REMOVAL WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. Fig. 12 MultiFunction Switch 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multi-function switch. INSTALLATION WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations The multiplexed headlamp switch is located on the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 741 Headlamp Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 742 Headlamp Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 743 Headlamp Switch: Description and Operation The multiplexed headlamp switch is located on the instrument panel. The headlamp switch controls the parking lamps, fog lamps and the headlamps. A separate switch in the module controls the interior lamps and instrument cluster illumination. This switch also contains a rheostat for controlling the illumination level of the cluster lamps. The multiplexed headlamp switch has an OFF, parking lamp, fog lamp and a headlamp on position. High beams are controlled by the multiplexed multifunction switch on the steering column. The fog lamps are illuminated by pulling back on the headlamp switch knob when in the parking lamp or headlamp ON position. The headlamp switch cannot be repaired. It must be replaced. The Instrument Cluster monitors the headlamp and multifunction switch operation. When the headlamp switch is rotated to the parking lamp or ON position the Instrument Cluster sends a J1850 message to the Front Control Module, which is mated to the power distribution center to become the Integrated Control Module, to illuminate the appropriate bulbs. When the multifunction switch is activated to the optical horn or high beam position the Instrument Cluster illuminates the high beam indicator and sends a J1850 message to the Front Control Module to illuminate the appropriate bulbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 744 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the left instrument panel bezel. 3. Disconnect the harness connector. Fig. 8 Headlamp Switch Removal 4. Remove the screws that secure the headlamp switch to the instrument panel bezel. 5. Remove the headlamp switch from the instrument panel bezel. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the headlamp switch to the left instrument panel bezal and secure with screws. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the instrument panel wire harness connector for the headlamp switch. 3. Position the left instrument panel bezal on to the instrument panel. 4. Install the cluster bezel onto the instrument panel (Fig 8) 5. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions Horn Switch: Service Precautions WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 748 Horn Switch: Description and Operation The horn switch is molded into the driver airbag trim cover. The horn switch cannot be serviced separately For service procedures, (Refer to RESTRAINTS/DRIVER AIRBAG - REMOVAL). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service Precautions > Page 749 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a DRB III scan tool and the proper Diagnostic Procedures manual. The DRB III scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic modules are sending and receiving the proper messages on the PCI data bus, and that the horns are being sent the proper hard wired outputs for them to perform their functions. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 753 Turn Signal Switch: Service Precautions WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 754 Turn Signal Switch: Description and Operation MULTI-FUNCTION SWITCH Turn Signal System The multi-function switch is a resistive MUX switch that is monitored by the Instrument Cluster. The turn signals are actuated with the lever on Multi-Function Switch. The signals are automatically turned OFF by a canceling cam (two lobes molded to the back of the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The Instrument Cluster monitors the multiplexed multifunction switch. In a turning event the Instrument Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator. At the same time, the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module (FCM). The FCM will respond by activating the appropriate relay in the Power Distribution Center. A chime will sound after the turn is completed if vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 755 Turn Signal Switch: Testing and Inspection MULTI FUNCTION SWITCH Multi-Function Switch Tests To test the turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to Electrical, Lamps/Lighting - Exterior, Multi-Function Switch, Removal, and Installation. 2. Using an ohmmeter check the resistance readings between multi-function switch pins. Refer to Wiring Diagrams for proper pin numbers and the MULTI-FUNCTION SWITCH TESTS table. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 756 Turn Signal Switch: Service and Repair MULTI FUNCTION SWITCH REMOVAL WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate battery negative cable. 2. Remove the steering wheel and the upper and lower steering column shrouds. Refer to Steering, Column, Shroud, Removal. 3. Disconnect the wire connector from the back of the multi-function switch. Fig. 12 MultiFunction Switch 4. Remove the screws retaining the multi-function switch to the steering column adapter collar. 5. Remove the multi-function switch. 6. Remove the screws retaining the clock spring to the multi-function switch. INSTALLATION WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO THE ELECTRICAL RESTRAINT SYSTEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. 1. Install the clock spring on the multifunction switch. 2. Position the switch on to the steering column. 3. Install the retaining screws. 4. Connect the wire harness connector. 5. Install the upper, lower steering column shrouds and the steering wheel. Refer to Steering, Column, Shroud, Installation. 6. Connect the battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 762 Battery Temperature Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 763 Battery Temperature Sensor: Description and Operation Fig. 1 Battery Temperature Sensor Location BATTERY TEMPERATURE SENSOR The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 764 Battery Temperature Sensor: Testing and Inspection Test 1 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/BATT (out of calibration) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 765 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (Fig. 1). 1. Remove battery Refer to Battery for procedures. 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector (Fig. 1). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery Refer to Battery for procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations The Camshaft Position Sensor (CMP) on this engine is located inside the distributor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 769 Camshaft Position Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 770 Camshaft Position Sensor: Description and Operation Fig. 6 CMP / Pulse Ring - 5.9L The CMP sensor on the 5.9L V-8 engine contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjuction with the Crankshaft Position (CKP) Sensor to differentiate between fuel injection and spark events. It is also used t synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: the interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 771 Camshaft Position Sensor: Service and Repair Fig. 9 Distributor And CMP Location - 5.9L REMOVAL The Camshaft Position Sensor (CMP) is located inside the distributor. Distributor removal is not necessary to remove camshaft position sensor. 1. Disconnect negative cable from battery. 2. Remove air cleaner tubing at throttle body, and at air filter housing. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift camshaft position sensor assembly from distributor housing. INSTALLATION The camshaft position sensor is located inside the distributor. 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect engine wiring harness to sensor pigtail harness. 3. Install rotor. 4. Install distributor cap. Tighten 2 mounting screws 5. Install air filter tubing. 6. Connect battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 11 Nm 96 In. Lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 775 Engine Coolant Temperature Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 776 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCM (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - 02 sensor closed loop times - Purge solenoid on/off times - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 777 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE SENSOR REMOVAL 3.7L The Engine Coolant Temperature (ECT) sensor is installed into a water jacket at front of intake manifold near rear of generator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor from the intake manifold. 4.7L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 778 The Engine Coolant Temperature (ECT) sensor is located near the front of the intake manifold. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the ECT sensor. 3. Remove the sensor from the intake manifold. 5.9L WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Disconnect the electrical connector from the sensor. 3. Engines with air conditioning: When removing the connector from the sensor, do not pull directly on the wiring harness. The connector is snapped onto the sensor. It is not equipped with a lock type tab. 4. Remove the sensor from the intake manifold. INSTALLATION 3.7L Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 779 1. Apply thread sealant to the sensor threads. 2. Install the sensor to the engine. 3. Tighten the sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect the electrical connector to the sensor. 5. Replace any lost engine coolant. 4.7L 1. Apply thread sealant to the sensor threads. 2. Install the sensor to the engine. 3. Tighten the sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect the electrical connector to the sensor. 5. Replace any lost engine coolant. 5.9L 1. Apply thread sealant to the sensor threads. 2. Install the sensor to the engine. 3. Tighten the sensor to 6 - 8 Nm (55 - 75 inch lbs.) torque. 4. Connect the electrical connector to the sensor. The sensor connector is symmetrical (not indexed). It can be connected to the sensor in either direction. 5. Refill the cooling system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm (70 in. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 783 Crankshaft Position Sensor: Locations The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 784 Crankshaft Position Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 785 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 786 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). It is bolted to the rear of the engine. Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 10 CKP Sensor Operation - 5.9L On this engine, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 787 Crankshaft Position Sensor: Service and Repair Fig. 13 CKP Removal/Installation - 5.9L REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Raise vehicle. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 791 Fuel Level Sensor: Description and Operation FUEL LEVEL SENDING UNIT / SENSOR The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 792 Fuel Level Sensor: Service and Repair REMOVAL Fig. 4 Location - Fuel Gauge Sending Unit The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation. Fig. 5 Fuel Gauge Sending Unit - R/I 2. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. 3. Disconnect 4-wire electrical connector from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 793 INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4-wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations 5.9L Fig. 23 IAT Sensor Location - 5.9L The intake manifold air temperature sensor is located in the front/side of the intake manifold. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 797 Intake Air Temperature Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 798 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-ON, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 799 Intake Air Temperature Sensor: Service and Repair Fig. 23 IAT Sensor Location - 5.9L REMOVAL The intake manifold air temperature sensor is located in the front/side of the intake manifold. 1. Clean dirt from intake manifold at sensor base. 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION The intake manifold air temperature sensor is located in the front/side of the intake manifold. 1. Install sensor to intake manifold. Tighten to 12 - 15 Nm (110 - 130 in. lbs.) torque. 2. Install electrical connector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications Map Sensor Mounting Screws 3 Nm 25 In. Lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 803 Manifold Pressure/Vacuum Sensor: Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the throttle body with 2 screws. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 804 Manifold Absolute Pressure Sensor (5.9L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 805 Manifold Pressure/Vacuum Sensor: Description and Operation MAP SENSOR The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0 - 15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-ON, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum. During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor ( TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively The PCM uses the MAP sensor input to aid in calculating the following: Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in.Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in.Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 806 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL Fig. 27 MAP Sensor - 5.9L Fig. 28 MAP Sensor L-Shaped Rubber Fitting - 5.9L The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. 1. Clean area around MAP sensor. 2. Remove two MAP sensor mounting bolts (screws). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION The MAP sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 807 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in. lbs.) torque. 4. Install air resonator box. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 812 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 813 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 815 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 816 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 818 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 821 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 823 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 824 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 825 Oil Pressure Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 826 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 827 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Engine Oil Pressure Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensors 30 Nm (22 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System Oxygen Sensor: Locations Engine Compartment/Exhaust System Fig. 29 O2S Location - 5.9L Federal Fig. 30 O2S Location - 5.9L California Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Engine Compartment/Exhaust System > Page 835 Oxygen Sensor: Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 836 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream Oxygen Sensor 1/2 Downstream Oxygen Sensor 2/1 Upstream (California/4.7L/5.9L) Oxygen Sensor 2/2 Downstream (California/4.7L/5.9L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 837 Oxygen Sensor: Service Precautions WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. CAUTION: - Never apply any type of grease to the oxygen sensor electrical connector; or attempt any soldering of the sensor wiring harness. - When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application O2 Sensor Configuration Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Application > Page 840 Oxygen Sensor: Application and ID OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 841 Oxygen Sensor: Description and Operation OXYGEN SENSOR The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. - California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions. The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing. Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation. - Oxygen Sensor Heater Relay : If 4 oxygen sensors are used, a separate heater relay is used to supply voltage to the sensors heating elements for only the 1/2 and 2/2 downstream sensors. Voltage for the other 2 sensor heating elements is supplied directly from the Powertrain Control Module (PCM) through a Pulse Width Module (PWM) method. Pulse Width Module (PWM): Voltage to the O2 sensor heating elements is supplied directly from the Powertrain Control Module (PCM) through two separate Pulse Width Module (PWM) low side drivers. PWM is used on both the upstream and downstream O2 sensors if equipped with a Federal Emissions Package, and only on the 2 upstream sensors (1/1 and 2/1) if equipped with a California Emissions Package. The main objective for a PWM driver is to avoid overheating of the O2 sensor heater element. With exhaust temperatures increasing with time and engine speed, it's not required to have a full-voltage duty-cycle on the O2 heater elements. To avoid the large simultaneous current surge needed to operate all 4 sensors, power is delayed to the 2 downstream heater elements by the PCM for approximately 2 seconds. Oxygen Sensor Heater Elements: The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 13 ohms. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 ° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. - Upstream Sensor - Federal Emissions Package : The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined will make the downstream sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency. - Downstream Sensor - Federal Emissions Package : The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 842 The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency. - Upstream Sensors - California Emissions Package : Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the #1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors . The PCM will change the air/fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct. The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. - Downstream Sensors - California Emissions Package : Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content). The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package. Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 843 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector; or attempt any soldering of the sensor wiring harness. Fig. 29 O2S Location - 5.9L Federal Fig. 30 O2S Location - 5.9L California Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 844 Fig. 31 O2S Location - 3.7L/4.7L Federal Fig. 32 O2S Location - 3.7L/4.7L California WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Application and ID > Page 845 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 Nm (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TPS Mounting Screws 7 Nm (60 in. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 849 Throttle Position Sensor: Locations 5.9L Fig. 41 TPS Location - 5.9L The TPS is located on the side of the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 850 Throttle Position Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 851 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade shaft. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 852 Throttle Position Sensor: Service and Repair Fig. 41 TPS Location - 5.9L REMOVAL The TPS is located on the side of the throttle body. 1. Remove air intake tube at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. Fig. 44 TPS Installation - 5.9L INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed Transmission Position Switch/Sensor: Description and Operation 45RFE 4 Speed 45RFE - Automatic Transmission DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 857 Transmission Position Switch/Sensor: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 260) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the JTEC engine controller. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 858 OPERATION As the switch moves through its linear motion (Fig. 261) contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 859 Transmission Position Switch/Sensor: Testing and Inspection 46RE - Automatic Transmission DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/ Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 860 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 861 Transmission Position Switch/Sensor: Service and Repair 46RE - Automatic Transmission REMOVAL 1. Raise vehicle and position drain pan under the Transmission Range Sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (Fig. 262) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 263). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 862 7. Remove the TRS mounting bracket (Fig. 264) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 265), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 863 3. Install the TRS (Fig. 266) into the mounting bracket with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 267). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Use Wiring Diagrams DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. General Information (Part 1 of 2) Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 868 General Information (Part 2 of 2) All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 869 piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Functions Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector, Ground and Splice Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 871 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 872 - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Symbols Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Take Outs The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine BUX ................................................................ ............................................................................................................................................. Built-Up-Export Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Section Identification and Information Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Connector Replacement REMOVAL 1. Disconnect battery Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 874 Fig. 10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 875 Fig. 11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Fig. 12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 877 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction. INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 878 Fig. 14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14). Fig. 15 Crimping Tool 4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15). Fig. 16 Solder Splice 5. Solder the connection together using rosin core type solder only (Fig. 16). CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Fig. 17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 17). Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Terminal Removing Tools 6932 And 8638 Terminal Removing Tool 6934 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation Troubleshooting Tests Fig.6 Electrostatic Discharge Symbol STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about 6 - 8 inches apart and watch the voltmeter/test lamp. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 883 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 mega-ohm or greater impedance rating. Ohmmeter Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 mega-ohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 884 Fig. 4 Probing Tool Probing Tools These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems, there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring, and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications TPS Mounting Screws 7 Nm (60 in. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 889 Throttle Position Sensor: Locations 5.9L Fig. 41 TPS Location - 5.9L The TPS is located on the side of the throttle body. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 890 Throttle Position Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 891 Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade shaft. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 892 Throttle Position Sensor: Service and Repair Fig. 41 TPS Location - 5.9L REMOVAL The TPS is located on the side of the throttle body. 1. Remove air intake tube at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body. Fig. 44 TPS Installation - 5.9L INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated. 1. Install TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in. lbs.) torque. 3. Manually operate throttle control lever by hand to check for any binding of TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations The Camshaft Position Sensor (CMP) on this engine is located inside the distributor. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 897 Camshaft Position Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 898 Camshaft Position Sensor: Description and Operation Fig. 6 CMP / Pulse Ring - 5.9L The CMP sensor on the 5.9L V-8 engine contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjuction with the Crankshaft Position (CKP) Sensor to differentiate between fuel injection and spark events. It is also used t synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: the interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 899 Camshaft Position Sensor: Service and Repair Fig. 9 Distributor And CMP Location - 5.9L REMOVAL The Camshaft Position Sensor (CMP) is located inside the distributor. Distributor removal is not necessary to remove camshaft position sensor. 1. Disconnect negative cable from battery. 2. Remove air cleaner tubing at throttle body, and at air filter housing. 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift camshaft position sensor assembly from distributor housing. INSTALLATION The camshaft position sensor is located inside the distributor. 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect engine wiring harness to sensor pigtail harness. 3. Install rotor. 4. Install distributor cap. Tighten 2 mounting screws 5. Install air filter tubing. 6. Connect battery cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor 8 Nm (70 in. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 903 Crankshaft Position Sensor: Locations The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 904 Crankshaft Position Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 905 Crankshaft Position Sensor: Service Precautions CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 906 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ringear). It is bolted to the rear of the engine. Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 10 CKP Sensor Operation - 5.9L On this engine, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The engine will not operate if the PCM does not receive a CKP sensor input. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 907 Crankshaft Position Sensor: Service and Repair Fig. 13 CKP Removal/Installation - 5.9L REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Raise vehicle. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL The ignition key must be in the key cylinder for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 916 Passenger Airbag ON/OFF Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 917 Air Bag Deactivation Switch: Service Precautions WARNING: ALWAYS CHECK THE PASSENGER AIRBAG ON-OFF SWITCH POSITION BEFORE DRIVING THE VEHICLE. A SWITCH IN THE WRONG POSITION INCREASES THE RISK OF SERIOUS INJURY OR DEATH IN A COLLISION. IGNORING THE AIRBAG WARNING LIGHT IN YOUR INSTRUMENT PANEL COULD MEAN THE PASSENGER AIRBAG ON-OFF SWITCH IS NOT FUNCTIONAL AND THE AIRBAG MAY DEPLOY IF AN IMPACT OCCURS. IF THE AIRBAG WARNING LIGHT TURNS ON WHILE DRIVING, THE AIRBAG ON-OFF SWITCH SETTING WILL REMAIN FUNCTIONAL FOR THAT KEY CYCLE. IF THE AIRBAG WARNING LIGHT COMES ON AGAIN AT THE NEXT KEY ON AND STAYS LIT FOR MORE THAN 6-8 SECONDS, THE ACM WILL DEFAULT TO PASSENGER AIRBAG ON. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 918 Air Bag Deactivation Switch: Description and Operation Fig. 38 Passenger Airbag ON/OFF Switch PASSENGER AIRBAG ON/OFF SWITCH The passenger airbag ON/OFF switch is standard equipment on all standard cab versions of this model when they are equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral red Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of instrument panel center bezel, near the center of instrument panel to make the OFF indicator visible to all front seat occupants. When the switch is in its installed position, the only components visible through the dedicated opening of the cluster bezel are the switch face plate and nomenclature and the key cylinder actuator. The "OFF' position of the switch is illuminated when this switch position is selected, while the "ON" position of the switch is designated by text imprinted upon the face plate of the switch, but is not illuminated. The remainder of the switch is concealed behind the switch face plate and the instrument panel center bezel. The passenger airbag ON/OFF switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch face plate with three small screws. The molded plastic face plate also has three integral mounting tabs that are used to secure the switch and face plate unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag ON/OFF switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag ON/OFF switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the owner's manual in the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and for 2 seconds at ignition ON for an indicator bulb test. The switch assembly is mounted in the center of instrument panel to make the OFF indicator visible to all front seat occupants. The ignition key is the only key or object that should ever be inserted into the switch. The ON/OFF switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag ON/OFF switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF indicator), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position), the OFF indicator will be extinguished and the passenger airbag is enabled. The passenger airbag ON/OFF switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module (ACM). The ACM continually monitors the resistance in these circuits to determine the switch position that has been selected and to provide circuit diagnostics. The ON/OFF switch ON position resistance is 175 - 190 ohms and the OFF position resistance is 820 - 870 ohms. If the ON/OFF switch circuits are open, shorted to ground or battery the ACM will set active and stored DTC. Upon receiving a switch diagnostic trouble code the airbag warning indicator, in the instrument cluster, will be turned ON by the ACM. Whenever the airbag warning indicator is illuminated, the ACM should be the first module interrogated. When the switch is in the OFF position, the ACM provides a ground input to the switch through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the OFF indicator of the switch. The ACM will also illuminate the OFF indicator of the switch for about 2 seconds each time the ignition switch is turned to the ON position as a bulb test. The ACM will also store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag ON/OFF switch or indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag ON/OFF switch or the ACM, a DRB III scan tool is Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 919 required. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 920 Air Bag Deactivation Switch: Service and Repair PASSENGER AIRBAG ON/OFF SWITCH REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel from the instrument panel. Fig. 39 Passenger Airbag ON/OFF Switch Remove/Install 3. Remove the three screws that secure the passenger airbag ON/OFF switch and face plate unit to the back of the center bezel. 4. Remove the passenger airbag ON/OFF switch and face plate from the center bezel as a unit. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Position the passenger airbag ON/OFF switch and face plate unit to the back of the center bezel. 2. Install and tighten the three screws that secure the passenger airbag ON/OFF switch face plate to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. (Refer to RESTRAINTS STANDARD PROCEDURE - VERIFICATION TEST). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation NOTE: The Impact Senor and the Safing Sensor are in the control modules, and can not be serviced separately. Airbag Control Module (ACM) The impact sensor and safing sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. The ACM cannot be repaired or adjusted and, if damaged or faulty it must be replaced. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electromechanical sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is a normally open switch that is used to verify the need for a front supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the front airbags or seat belt tensioners to deploy. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor and the safing sensor indicate an impact that is severe enough to require front supplemental restraint system protection and, based upon the status of the passenger airbag on/off switch input and the severity of the monitored impact, determines what combination of seat belt tensioner and front airbag deployment is required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the seat belt tensioners and dual front airbags. Side Impact Airbag Control Module (SIACM) The impact sensor internal to the SIACM is calibrated for the specific vehicle, and is only serviced as a unit with the SIACM. The SIACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. An electronic impact sensor is contained within the SIACM. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the SIACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates a side impact that is severe enough to require side curtain airbag protection. When the programmed conditions are met, the SIACM sends the proper electrical signals to deploy the side curtain airbag. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation NOTE: The Impact Senor and the Safing Sensor are in the control modules, and can not be serviced separately. Airbag Control Module (ACM) The impact sensor and safing sensor internal to the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. The ACM cannot be repaired or adjusted and, if damaged or faulty it must be replaced. Two sensors are contained within the ACM, an electronic impact sensor and a safing sensor. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electromechanical sensor within the ACM that provides an additional logic input to the ACM microprocessor. The safing sensor is a normally open switch that is used to verify the need for a front supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the electronic impact sensor, and must be closed in order for the front airbags or seat belt tensioners to deploy. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor and the safing sensor indicate an impact that is severe enough to require front supplemental restraint system protection and, based upon the status of the passenger airbag on/off switch input and the severity of the monitored impact, determines what combination of seat belt tensioner and front airbag deployment is required for each front seating position. When the programmed conditions are met, the ACM sends the proper electrical signals to deploy the seat belt tensioners and dual front airbags. Side Impact Airbag Control Module (SIACM) The impact sensor internal to the SIACM is calibrated for the specific vehicle, and is only serviced as a unit with the SIACM. The SIACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. An electronic impact sensor is contained within the SIACM. The electronic impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. A pre-programmed decision algorithm in the SIACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates a side impact that is severe enough to require side curtain airbag protection. When the programmed conditions are met, the SIACM sends the proper electrical signals to deploy the side curtain airbag. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Fig. 46 Seat Belt Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 930 Seat Belt Switch - Driver Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 931 Seat Belt Buckle Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 932 Seat Belt Buckle Switch: Description and Operation Fig. 46 Seat Belt Switch SEAT BELT SWITCH The seat belt switch is a small, normally open, single pole, single throw, leaf contact, momentary switch. Only one seat belt switch is installed in the vehicle, and it is integral to the buckle of the driver side front seat belt buckle-half, located on the inboard side of the driver side front seat track. The seat belt switch is connected to the vehicle electrical system through a two-wire pigtail wire and connector on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired and, if faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the instrument cluster. When the driver side seat belt tip-half is inserted in the seat belt buckle, the switch closes the path to ground; and, when the driver side seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 933 Seat Belt Buckle Switch: Testing and Inspection Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Disconnect the seat belt switch pigtail wire connector from the seat wire harness connector for the seat belt switch on the inboard side of the driver side front seat forward of the seat belt buckle-half anchor. Check for continuity between the seat belt switch sense circuit and the ground circuit cavities of the seat belt switch pigtail wire connector. There should be continuity with the seat belt buckled, and no continuity with the seat belt unbuckled. If OK, go to Step 2. If not OK, replace the faulty seat belt buckle-half assembly 2. Check for continuity between the ground circuit cavity in the seat wire harness connector for the seat belt switch and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground (G640) as required. 3. Remove the instrument cluster from the instrument panel. Check for continuity between the seat belt switch sense circuit cavity of the seat wire harness connector for the seat belt switch and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the shorted seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. 4. Check for continuity between the seat belt switch sense circuit cavities of the seat wire harness connector for the seat belt switch and the instrument panel wire harness connector (Connector C2) for the instrument cluster. There should be continuity. If OK, test and replace the faulty instrument cluster as required. (Refer to INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If not OK, repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as required. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Fig. 1 Battery Temperature Sensor Location The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 938 Battery Temperature Sensor Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 939 Battery Temperature Sensor: Description and Operation Fig. 1 Battery Temperature Sensor Location BATTERY TEMPERATURE SENSOR The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20 °F. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 940 Battery Temperature Sensor: Testing and Inspection Test 1 SYMPTOM CHECKING THE AMBIENT/BATTERY TEMPERATURE SENSOR POSSIBLE CAUSES - Ambient/BATT (out of calibration) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 941 Battery Temperature Sensor: Service and Repair Fig. 1 Battery Temperature Sensor Location REMOVAL The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (Fig. 1). 1. Remove battery Refer to Battery for procedures. 2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector (Fig. 1). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. 1. Pull electrical connector up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery Refer to Battery for procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Clutch Interlock Brake Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Page 945 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH DESCRIPTION A clutch pedal position (interlock) switch is mounted on the clutch master cylinder push rod (Fig. 14). The switch is actuated by clutch pedal movement. OPERATION The clutch pedal position switch is used to prevent starter motor engagement unless the clutch pedal is depressed. An input from this switch is also used to either shut down and/or prevent operation of the speed control system when the clutch pedal is depressed. The position switch is an integral part of the clutch master cylinder push rod and is not serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Page 946 Clutch Switch: Testing and Inspection DIAGNOSIS AND TESTING - CLUTCH PEDAL POSITION SWITCH 1. Locate clutch switch 2-wire electrical connector. This will be the test point. This connector is attached to pedal support bracket located under instrument panel to left of clutch pedal (Fig. 15). Disconnect wiring at this point. 2. Check for switch continuity with an ohmmeter while operating clutch pedal up and down. Continuity should be broken and reapplied each time pedal is pressed. 3. If continuity is not present, or is always present at any pedal position, replace switch. Switch is not serviced separately. Replace clutch master cylinder. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL The ignition key must be in the key cylinder for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. INSTALLATION The ignition key must be in the key cylinder for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 45RFE 4 Speed Fluid Pressure Sensor/Switch: Description and Operation 45RFE 4 Speed 45RFE - AUTOMATIC TRANSMISSION Line Pressure (LP) Sensor / DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 957 Fluid Pressure Sensor/Switch: Description and Operation 46RE (A-518) 4 Speed GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve (Fig. 85). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Page 958 Fluid Pressure Sensor/Switch: Service and Repair 45RFE - Automatic Transmission Line Pressure (LP) Sensor / REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (Fig. 92). 4. Remove the bolt holding the line pressure sensor to the transmission case. 5. Remove the line pressure sensor from the transmission case. INSTALLATION 1. Install the line pressure sensor into the transmission case. 2. Install the bolt to hold the line pressure sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams Overdrive Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 45RFE 4 Speed Overdrive Switch: Description and Operation 45RFE 4 Speed 45RFE - Automatic Transmission OVERDRIVE OFF SWITCH The overdrive OFF (control) switch is located in the shift lever arm (Fig. 106). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 964 Overdrive Switch: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission OVERDRIVE OFF SWITCH The overdrive OFF (control) switch is located in the shift lever arm (Fig. 135). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 965 Overdrive Switch: Testing and Inspection ELECTRICAL CONTROLS The overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 45RFE 4 Speed Overdrive Switch: Service and Repair 45RFE 4 Speed 45RFE - AUTOMATIC TRANSMISSION REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 107). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 108) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 45RFE 4 Speed > Page 968 2. Install the overdrive off switch into the connector (Fig. 109) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 45RFE 4 Speed > Page 969 Overdrive Switch: Service and Repair 46RE (A-518) 4 Speed 46RE - AUTOMATIC TRANSMISSION REMOVAL 1. Using a plastic trim tool, remove the overdrive off switch retainer from the shift lever (Fig. 136). 2. Pull the switch outwards to release it from the connector in the lever (Fig. 137) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector out of the lever just enough to grasp it. CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 45RFE 4 Speed > Page 970 2. Install the overdrive off switch into the connector (Fig. 138) 3. Push the overdrive off switch and wiring into the shift lever. 4. Install the overdrive off switch retainer onto the shift lever. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 974 Transmission Range Sensor (5.9L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed Transmission Position Switch/Sensor: Description and Operation 45RFE 4 Speed 45RFE - Automatic Transmission DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 979 Transmission Position Switch/Sensor: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) (Fig. 260) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the JTEC engine controller. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 980 OPERATION As the switch moves through its linear motion (Fig. 261) contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 981 Transmission Position Switch/Sensor: Testing and Inspection 46RE - Automatic Transmission DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/ Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Cluster Resistance Signal and the Cluster Signal Return pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 982 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 983 Transmission Position Switch/Sensor: Service and Repair 46RE - Automatic Transmission REMOVAL 1. Raise vehicle and position drain pan under the Transmission Range Sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (Fig. 262) from the TRS mounting bracket by pulling it straight out of the bracket. 6. Loosen the TRS mounting bracket in the transmission case using Adapter 8581 (Fig. 263). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 984 7. Remove the TRS mounting bracket (Fig. 264) from the transmission case. INSTALLATION 1. Move the transmission manual shaft lever to the manual LOW position. 2. Install the TRS mounting bracket into the transmission case. Using Adapter 8581 (Fig. 265), tighten the mounting bracket to 34 Nm (300 inch lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 985 3. Install the TRS (Fig. 266) into the mounting bracket with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 3.4 Nm (30 inch lbs.). 5. Verify proper sensor operation (Fig. 267). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 45RFE 4 Speed Transmission Speed Sensor: Specifications 45RFE 4 Speed Sensor, Trans Speed ........................................................................................................................... ..................................................... 27 Nm (20 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > 45RFE 4 Speed > Page 990 Transmission Speed Sensor: Specifications 46RE (A-518) 4 Speed Bolt, Input Speed Sensor ..................................................................................................................... ........................................... 11.8 Nm (105 inch lbs.) Bolt, Output Speed Sensor .............................................................................................................................................................. 11.8 Nm(105 inch lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 991 Output Speed Sensor (5.9L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed Transmission Speed Sensor: Description and Operation 45RFE 4 Speed Input Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor 45RFE - Automatic Transmission DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 994 Transmission Speed Sensor: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission SPEED SENSOR / DESCRIPTION The speed sensor (Fig. 245) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor Transmission Speed Sensor: Service and Repair Input Speed Sensor 45RFE - Automatic Transmission REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (Fig. 91). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor into the transmission case. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Speed Sensor > Page 997 Transmission Speed Sensor: Service and Repair Output Speed Sensor 45RFE - Automatic Transmission REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (Fig. 105). 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. INSTALLATION 1. Install the output speed sensor into the transmission case. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 11.9 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications Transmission Temperature Sensor/Switch: Electrical Specifications 46RE - Automatic Transmission TRANSMISSION TEMPERATURE SENSOR DESCRIPTION Transmission fluid temperature readings are supplied to the transmission control module by the thermistor (Fig. 268). The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 2000 ohms. The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. OPERATION The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10°C (50°F). If fluid temperature exceeds 126°C (260°F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110°C (230°F). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Electrical Specifications > Page 1002 Transmission Temperature Sensor/Switch: Pressure, Vacuum and Temperature Specifications 46RE - Automatic Transmission TRANSMISSION TEMPERATURE SENSOR DESCRIPTION Transmission fluid temperature readings are supplied to the transmission control module by the thermistor (Fig. 268). The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 2000 ohms. The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. OPERATION The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10°C (50°F). If fluid temperature exceeds 126°C (260°F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110°C (230°F). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 45RFE 4 Speed Transmission Temperature Sensor/Switch: Description and Operation 45RFE 4 Speed Transmission Temperature Sensor 45RFE - Automatic Transmission DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Transmission Range Sensor 45RFE - Automatic Transmission DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. - Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 45RFE 4 Speed > Page 1005 Transmission Temperature Sensor/Switch: Description and Operation 46RE (A-518) 4 Speed 46RE - Automatic Transmission TRANSMISSION TEMPERATURE SENSOR DESCRIPTION Transmission fluid temperature readings are supplied to the transmission control module by the thermistor (Fig. 268). The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 2000 ohms. The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. OPERATION The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10°C (50°F). If fluid temperature exceeds 126°C (260°F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110°C (230°F). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Transfer Case Selector Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 1010 Four Wheel Drive Selector Switch: Description and Operation NV243 - Transfer Case DESCRIPTION The selector switch assembly (Fig. 89) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four Light Emitting Diode's (LED's) to indicate the transfer case position and whether a shift is in progress. OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: SELECTOR SWITCH INTERPRETATION SELECTOR SWITCH INTERPRETATION For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 1011 - an invalid fault position. The LED's in the selector assembly are illuminated mashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Transfer Case Mode Sensor Transfer Case Position Sensor (4.7L/5.9L) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV241/GEN II - Transfer Case Gear Sensor/Switch: Description and Operation NV241/GEN II - Transfer Case NV241/GEN II - Transfer Case DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (±0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. OPERATING MODE VERSUS RESISTANCE OPERATION During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position (Fig. 92). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV241/GEN II - Transfer Case > Page 1017 Gear Sensor/Switch: Description and Operation NV243 - Transfer Case DESCRIPTION The transfer case mode sensor (Fig. 88) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (± 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (±50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. SECTOR ANGLES VS. TRANSFER CASE POSITION SECTOR ANGLES VS. TRANSFER CASE POSITION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV241/GEN II - Transfer Case > Page 1018 MODE SENSOR CHANNEL STATES MODE SENSOR CHANNEL STATES Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Page 1019 Gear Sensor/Switch: Service and Repair NV241/GEN II - Transfer Case REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. INSTALLATION 1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 20 - 34 Nm (15 - 25 ft. lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams Power Window Switch: Diagrams Power Window Switch - Left Rear Power Window Switch - Passenger Power Window Switch - Right Rear Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1024 Power Window Switch: Description and Operation The power window switches control the battery and ground feeds to the power window motors. The passenger door power window switches receive their battery and ground feeds through the circuitry of the drivers window switch. When the power window lockout switch is in the Lock position, the battery feed for the passenger door window switches is interrupted. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1025 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED (s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin- out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fuse in the Integrated Power Module (IPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the OFF position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the Driver Door Module (Refer to POWER LOCKS/DOOR MODULE DIAGNOSIS AND TESTING) for service procedures. Unplug the wire harness connector from the switch unit. Passenger Door Switch 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the OFF, Up and Down switch positions. If OK, (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1026 Power Window Switch: Service and Repair REMOVAL Front Passenger 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, gently pry the switch from the door trim panel. 3. Disconnect the electrical harness connector from the window switch. Rear Passenger 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION Front Passenger 1. Connect electrical harness connector to switch. 2. Position switch to door trim panel. 3. Connect battery negative cable. Rear Passenger 1. Install switch to door trim panel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 1031 Washer Fluid Level Switch: Description and Operation Fig. 5 Washer Fluid Level Switch The washer fluid level switch is a single pole, single throw reed-type switch mounted on the outboard side of the rearward facing surface near the bottom of the washer reservoir. Only the molded plastic switch mounting flange and the integral connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. A small, molded plastic float has two pivot pins near its center that are snapped into two receptacles near the ends of two stanchions that extend toward the float from the switch nipple formation. A small magnet is secured within the end of the float nearest the switch nipple formation, and a reed switch is concealed within the nipple. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field is applied to the reed switch, and the contacts of the normally open reed switch close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right headlamp and dash wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FMC senses the ground on the washer fluid switch sense circuit. The FMC is programmed to respond to this input by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the operation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer fluid indicators requires the use of a DRB III scan tool. Refer to the appropriate diagnostic information. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 1032 Washer Fluid Level Switch: Service and Repair REMOVAL The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. Fig. 6 Washer Fluid Level Switch Remove/Install 4. Disconnect the right headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle. NOTE: The pivoting float of the washer fluid level switch must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and in an upright position, the pivoting float will orient itself to the horizontal position when the switch connector receptacle is pointed straight upwards. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the back of the reservoir sump. Care must be taken not to damage the reservoir. 6. Remove the washer fluid level switch from the washer reservoir. 7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir. 2. Insert the float of the washer fluid level switch through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. 3. Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. 4. Reconnect the right headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle. 5. Reconnect the removed washer hose to the barbed outlet nipple of the washer pump/motor unit. 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. 8. Close and latch the hood. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi-Function Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Toe-In Specification Revision Alignment: Technical Service Bulletins Steering/Suspension - Toe-In Specification Revision NUMBER: 02-003-02 GROUP: Front Suspension DATE: June 17, 2002 SUBJECT: Toe In Specification Change OVERVIEW: This bulletin involves an update to the toe in specification for front end alignments. MODELS: 2000 - 2002 BR/BE Ram Truck DISCUSSION: The specification for toe in has been revised to 0.2° +/- 0.1° total toe in. This change has been shown to improve straight ahead driving performance and should be used whenever a front end alignment is performed. POLICY: Information Only Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1044 Alignment: Specifications ALIGNMENT NOTE: All alignment specifications are in degrees. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1045 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off center. The wheel toe position is the final front wheel alignment adjustment THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection Alignment: Service and Repair Pre-Alignment Inspection DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. On 4x4 vehicles check suspension height. 7. Road test the vehicle. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1048 Alignment: Service and Repair Wheel Alignment Camber and Caster Adjustment STANDARD PROCEDURE-CAMBER AND CASTER ADJUSTMENT NOTE: 4X4 SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. Camber and caster angle adjustments involve changing the position of the upper control arm in conjunction with the slotted holes in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. Camber, Caster and Toe Adjustment STANDARD PROCEDURE-CAMBER, CASTER AND TOE ADJUSTMENT NOTE: 4X4 SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. Camber and caster angle adjustments involve changing the position of the upper control arm with the slots in the frame brackets using special tool 8876 to move the upper control arm outwards for proper adjustment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1049 NOTE: When the upper control arm pivot bolts are loosened the upper control arm will normally go inwards toward the frame automatically with the weight of the vehicle. CASTER Moving the front or rear position of the upper control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction using special tool 8876 to move the upper control arm for proper adjustment. To increase positive caster angle, move the rear position of the upper control arm inward (toward the engine). Move the front of the upper control arm outward (away from the engine) slightly until the original camber angle is obtained using special tool 8876 to move the upper control arm for proper adjustment. CAMBER Move both pivot bolts of the upper control arm together in or out. This will change the camber angle significantly and little effect on the caster angle using special tool 8876 to move the upper control arm for proper adjustment. After adjustment is made tighten the upper control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod as necessary. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Pre-Alignment Inspection > Page 1050 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). 5. Verify the specifications 6. Turn off engine. Toe Adjustment STANDARD PROCEDURE-TOE ADJUSTMENT 4X4 SUSPENSION HEIGHT MEASUREMENT MUST BE PERFORMED BEFORE AN ALIGNMENT. The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 339 kPa +/- 34 kPa (49.2 psi +/- 2 psi) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check Fuel Pressure: Testing and Inspection Fuel Delivery Check Tests 1 - 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1057 Tests 3 - 5 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1058 Tests 6 - 10 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump capacity (volume) out of SPECS - Fuel pump relay fused B+ circuit - Fuel pump relay output circuit open Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1059 - Fuel pump ground circuit open/high resistance - Fuel pump module Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1060 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test FUEL PRESSURE LEAK DOWN TEST Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). - Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. Refer to Quick Connect Fittings for procedures. On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Obtain correct Fuel Line Pressure Test Adapter Tool Hose. Tool number 6539 is used for 5/16" fuel lines and tool number 6631 is used for 3/8" fuel lines. Fig. 2 Connecting Adapter Tool - Typical 3. Connect correct Fuel Line Pressure Test Adapter Tool Hose between disconnected fuel line and fuel rail (Fig. 2). 4. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. The DRB(R) III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 5. Start engine and bring to normal operating temperature. 6. Observe test gauge. Normal operating pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi). 7. Shut engine off. 8. Pressure should not fall below 30 psi for five minutes. 9. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 10. Again, start engine and bring to normal operating temperature. 11. Shut engine off. 12. Testing for fuel injector or fuel rail leakage: Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1061 13. Testing for fuel pump check valve, filter, regulator check valve or fuel tube/line leakage: Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump, fuel filter or fuel pressure regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the pressure regulator. A slow loss of pressure usually indicates a defective check valve in the bottom of the fuel pump module. The check valves are not serviced separately Also, the electric fuel pump is not serviced separately. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1062 Fuel Pressure: Testing and Inspection Fuel Pump Pressure Test Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere in this group. Check Valve Operation: The fuel pump module contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 - 2 seconds) rise to specification. The fuel system is equipped with a combination fuel filter / fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. Fig. 16 Typical Gauge Installation 1. Remove protective cap at fuel rail test port. Connect the 0 - 414 kPa (0 - 60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail (Fig. 16). The DRB(R) III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa ± 34 kPa (49.2 psi ± 5 psi) at idle. 3. If engine runs, but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, but specifications for either the Fuel Pump Capacity, Fuel Pump Amperage or Fuel Pressure Leak Down Tests were not met, replace fuel pump module. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel pump module. Refer to Fuel Pump Module Removal/Installation. 5. Install protective cap to fuel rail test port. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp (Fig. 4) and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (Fig. 4) from housing cover (spring clips retain cover to housing). 3. Release housing cover from locating tabs on housing (Fig. 4) and remove cover. 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp (Fig. 4) and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1067 2. Lift entire housing assembly from 4 locating pins (Fig. 5). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (Fig. 4). 3. Pry up 4 spring clips (Fig. 4) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 1073 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1074 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order - 5.2/5.9L V-8 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1079 Firing Order - 5.2/5.9L V-8 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order - 5.2/5.9L V-8 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SPARK PLUG CABLE RESISTANCE Minimum Maximum 250 ohms per inch 1000 ohms per inch 3000 ohms per foot 12,000 ohms per foot Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1087 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark plug cables are sometimes referred to as secondary ignition wires, or secondary ignition cables. The spark plug cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1088 Ignition Cable: Testing and Inspection SPARK PLUG CABLE Cable routing is important on certain engines. To prevent possible ignition crossfire, be sure the cables are clipped into the plastic routing looms. Try to prevent any one cable from contacting another. Before removing cables, note their original location and routing. Never allow one cable to be twisted around another. Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Fig. 33 Heat Shields - 5.9L On 5.9L engines, spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. Testing When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1089 To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1090 Ignition Cable: Service and Repair SPARK PLUG CABLE Fig. 34 Cable Removal REMOVAL CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (112 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. INSTALLATION Install cables into the proper engine cylinder firing order sequence. Refer to Specifications. When replacing the spark plug and coil cables, route the cables correctly and secure them in the proper retainers. Failure to route the cables properly may cause the radio to reproduce ignition noise. It could also cause cross-ignition of the plugs, or, may short-circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig.27 Cap Inspection - External - Typical Fig.28 Cap Inspection - Internal - Typical DIAGNOSIS AND TESTING - DISTRIBUTOR 1. Remove the distributor cap and wipe it clean with a dry lint free cloth. 2. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). 3. Replace any cap that displays charred or eroded terminals. The machined surface of a terminal end (faces toward rotor) will indicate some evidence of erosion from normal operation. 4. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig.29 Rotor Inspection - Typical DIAGNOSIS AND TESTING - IGNITION ROTOR Visually inspect the rotor for cracks, evidence of corrosion or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric varnish compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Type Spark Plug: Specifications Spark Plug Type Spark Plug Type .................................................................................................................................. .............................................. RC12LC4 (Champion) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Type > Page 1102 Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ................................................................................................................................... .................................................... 1.01 mm (0.040 in.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Type > Page 1103 Spark Plug: Specifications Spark Plug Torque Spark Plugs - 5.9L V-8 ........................................................................................................................ ..................................................... 41 Nm (30 ft. lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1104 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .............................................. RC12LC4 (Champion) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1105 Spark Plug: Description and Operation Resistor type spark plugs are used. Spark plug resistance values range from 6,000 to 20,000 ohms (when checked with at least a 1000 volt spark plug tester). Do not use an ohmmeter to check the resistance values of the spark plugs. Inaccurate readings will result. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Lubrication and Maintenance Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1106 Spark Plug: Testing and Inspection SPARK PLUG CONDITIONS Fig. 22 Normal Operation And Cold (Carbon) Fouling Normal Operating The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 3200 km (2000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Cold Fouling/Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips). Wet Fouling Or Gas Fouling A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1107 Fig. 23 Oil Or Ash Encrusted Oil Or Ash Encrusted If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber. Fig. 24 Electrode Gap Bridging Electrode Gap Bridging Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1108 Fig. 25 Scavenger Deposits Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures. Fig. 26 Chipped Electrode Insulator Chipped Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1109 Fig. 27 Preignition Damage Preignition Damage Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.) Fig. 28 Spark Plug Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Replacement Spark Plug: Service and Repair Spark Plug Replacement REMOVAL Fig. 29 Heat Shields - 5.9L On this engines, spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. Fig. 30 Cable Removal - 5.9L 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. Refer to Spark Plug Condition in the Diagnostics and Testing section of this group. INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Replacement > Page 1112 When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs Refer to torque specifications. 3. Install spark plug cables to spark plugs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug Replacement > Page 1113 Spark Plug: Service and Repair Spark Plug Cleaning and Adjustment CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Fig.51 Setting Spark Plug Gap - Typical Adjust spark plug gap with a gap gauging tool. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Cylinder Compression Pressure 689.5 kPa (100 psi) Maximum Variation Between Cylinders 25 % Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1117 Compression Check: Testing and Inspection DIAGNOSIS AND TESTING-CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disconnect the ignition coil. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the third revolution. Continue the test for the remaining cylinders. Refer to SPECIFICATIONS for the correct engine compression pressures. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1124 Without A/C Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1125 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT Part 1 of 2 Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1126 Part 2 of 2 ACCESSORY DRIVE BELT DIAGNOSIS CHART VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 8), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 8). Also replace the belt if it has excessive wear, frayed cords or severe glazing. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1127 Drive Belt: Service and Repair DRIVE BELTS REMOVAL NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Drive belts on these engines are equipped with a spring loaded automatic belt tensioner (Fig. 9). This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner (Fig. 9). 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. INSTALLATION Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1128 CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 10) (Fig. 11) for correct engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except idler pulley This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner (Fig. 9). 3. Rotate socket/wrench clockwise. Place belt over idler pulley Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT REMOVAL Filter Element Only Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp (Fig. 4) and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (Fig. 4) from housing cover (spring clips retain cover to housing). 3. Release housing cover from locating tabs on housing (Fig. 4) and remove cover. 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly 1. Loosen clamp (Fig. 4) and disconnect air duct at air cleaner cover. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1134 2. Lift entire housing assembly from 4 locating pins (Fig. 5). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (Fig. 4). 3. Pry up 4 spring clips (Fig. 4) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3.4 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 Nm (40 inch lbs.) torque. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > 45RFE 4 Speed Fluid Filter - A/T: Specifications 45RFE 4 Speed Screw, Primary Fluid Filter .................................................................................................................. .............................................. 4.5 Nm (40 inch lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > 45RFE 4 Speed > Page 1142 Fluid Filter - A/T: Specifications 46RE (A-518) 4 Speed Screws, Fluid Filter .............................................................................................................................. ................................................. 4 Nm (35 inch lbs.) Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check Fluid Filter - A/T: Service and Repair Fluid Level and Condition Check Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transmission recondition is needed. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. FLUID LEVEL CHECK PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 °C (180 °F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. Fig. 72 7. Remove dipstick (Fig. 72) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar ATF +4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1145 Fluid Filter - A/T: Service and Repair Fluid and Filter Replacement STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission (Fig. 98). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter to valve body (Fig. 99). 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris, refer to Testing and Inspection. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1146 Check the adjustment of the front and rear bands, adjust if necessary. CLEANING 1. Using a suitable solvent, clean pan and magnet. INSTALLATION 1. Position a new transmission oil filter onto the valve body 2. Install the screws to hold the filter to the valve body Tighten the screws to 4 Nm (35 inch lbs.). 3. Clean the gasket surfaces of the transmission oil pan and transmission pan rail. NOTE:The original transmission pan oil gasket is reusable, inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket onto the oil pan. 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. For OE type reusable pan gasket: tighten the bolts to 13.6 Nm (125 inch lbs.). For aftermarket pan gasket: tighten the bolts to 17 Nm (150 inch lbs.). 7. Lower vehicle and fill transmission. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Level and Condition Check > Page 1147 Fluid Filter - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4, Automatic Transmission Fluid, to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information Fuel Pressure Release: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Technician Safety Information > Page 1153 Fuel Pressure Release: Vehicle Damage Warnings CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1154 Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 1158 Fuel Pump Pickup Filter: Service and Repair INLET FILTER REMOVAL Fig. 28 Fuel Pump Inlet Filter The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 28). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. Refer to Fuel Tank Removal/Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 28). The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair Oil Filter: Service and Repair OIL FILTER REMOVAL All engines are equipped with a high quality full flow, disposable type oil filter. Daimler Chrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss (Fig. 55). 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. 5. With a wiping cloth, clean the gasket sealing surface (Fig. 56) of oil and grime. 6. Install new filter. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 56) hand tighten filter one full turn, do not over tighten. 3. Add oil. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications A/C COMPRESOR LINE MANIFOLD FASTENER 28 (+/- 6) Nm 21 (+/- 4) Ft. Lbs 250 (+/- 50) In. Lbs) SUCTION LINE TO ACCUMULATOR FITTING 9 Nm 6.6 Ft. Lbs 80 In. Lbs Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1166 Hose/Line HVAC: Service Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. There are two types of refrigerant fittings: - All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak. - Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing. Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench. The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again. Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210. The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system. When it is necessary to open the refrigerant system, have everything needed to service the system ready The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed. All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry All tools and equipment must be designed for R-134a refrigerant. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1167 Hose/Line HVAC: Description and Operation REFRIGERANT LINE The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from an exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled with other components of the HVAC system with either 3 - O-ring spring lock couplings or dual axes seals. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the high pressure transducer. Fig. 5 A/C Discharge Line 4. Disconnect the discharge line refrigerant line fitting from the condenser inlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Disconnect the connection that secures the suction line fitting to the accumulator outlet. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the screw that secures the suction and discharge line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 7. Remove the suction and discharge line assembly from the vehicle. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the tape or plugs from the suction and discharge line manifold and the compressor. Install the suction and discharge line manifold to the compressor. Tighten the fastener to 28 Nm (250 in. lbs.). 2. Remove the tape or plugs from the suction line and the accumulator outlet fittings. Install the suction line to the accumulator outlet and install fastener. 3. Remove the tape or plugs from the refrigerant line fittings on the discharge line and the condenser inlet tube. Connect the discharge line refrigerant line coupler to the condenser inlet tube. 4. Plug in the wire harness connector to the high pressure transducer switch. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1170 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Disconnect the liquid line refrigerant line couplers at the condenser outlet and the evaporator inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. Fig. 6 A/C Liquid Line 4. Disengage any clips that secure the liquid line to the inner fender shield or cross brace.. 5. Remove the liquid line from the vehicle. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Install the liquid line into any clips on the inner fender shield and the dash panel. 2. Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line to the condenser and the evaporator. 3. Connect the battery negative cable. 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1171 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the a/c high pressure transducer. 4. Disconnect the suction line refrigerant line coupler at the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Remove the suction and discharge line assembly from the vehicle. INSTALLATION WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Remove the tape or plugs from all of the refrigerant line fittings. Connect the suction line refrigerant line coupler to the accumulator. 2. Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 Nm (180 in. lbs.). 3. Install the refrigerant line manifold to the compressor. Tighten the mounting bolt to 22 Nm (200 in. lbs.). 4. Plug in the wire harness connector to the A/C high pressure transducer. 5. Connect the battery negative cable. 6. Evacuate the refrigerant system. 7. Charge the refrigerant system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-003-02 > Apr > 02 > Power Steering - Hissing Sound Power Steering Line/Hose: Customer Interest Power Steering - Hissing Sound NUMBER: 19-003-02 GROUP: Steering DATE: April 15, 2002 SUBJECT: Hissing Sound Coming From The Power Steering System On Vehicles Equipped With Hydroboost Brakes OVERVIEW: This bulletin involves Replacing the power steering hoses connecting the Hydroboost to the power steering pump and gear. MODELS: 1997 - 2002 BR/BE Ram Truck SYMPTOM/CONDITION: A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. DIAGNOSIS: If the vehicle exhibits the condition perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Drain the power steering fluid from the system. 2. Remove the pressure hose from the power steering pump to the Hydroboost. 3. Install the new hose, p/n 05086529AA. 4. Remove the pressure hose from the Hydroboost to the steering gear. 5. Install the new hose, p/n 05086532AA. 6. Check the routing of the hoses to ensure no interference problems exist. Use tie straps to secure the hoses if necessary. 7. Fill the system with power steering fluid and operate the steering system to purge any air from the system POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-003-02 > Apr > 02 > Power Steering Hissing Sound Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Hissing Sound NUMBER: 19-003-02 GROUP: Steering DATE: April 15, 2002 SUBJECT: Hissing Sound Coming From The Power Steering System On Vehicles Equipped With Hydroboost Brakes OVERVIEW: This bulletin involves Replacing the power steering hoses connecting the Hydroboost to the power steering pump and gear. MODELS: 1997 - 2002 BR/BE Ram Truck SYMPTOM/CONDITION: A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. DIAGNOSIS: If the vehicle exhibits the condition perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Drain the power steering fluid from the system. 2. Remove the pressure hose from the power steering pump to the Hydroboost. 3. Install the new hose, p/n 05086529AA. 4. Remove the pressure hose from the Hydroboost to the steering gear. 5. Install the new hose, p/n 05086532AA. 6. Check the routing of the hoses to ensure no interference problems exist. Use tie straps to secure the hoses if necessary. 7. Fill the system with power steering fluid and operate the steering system to purge any air from the system POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1185 Power Steering Line/Hose: Specifications Power Steering Line Pressure Line 27 ft. lbs. Power Steering Line Return Line 27 ft. lbs. Power Steering Line Pressure Line To Pump 27 ft. lbs. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure REMOVAL- PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION - PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1188 Power Steering Line/Hose: Service and Repair Hose - Return Return Hose - Gear to Cooler REMOVAL - RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION - RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose at the gear. Tighten the hose to 71 Nm (52 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Return Hose - Reservoir to Cooler REMOVAL - RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION - RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1193 Brake Fluid: Service Precautions WARNING: Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident. CAUTION: DO not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1194 Brake Fluid: Service and Repair The fluid of the master cylinder should be checked when performing under the hood service, or immediately if the brake system warning lamp indicates system failure. The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a "MAX" dot and an "MIN" dot. The fluid level must be kept within these two dots. Do not add fluid above the full mark, because leakage may occur at the cap. With disc brakes the fluid level can be expected to fall as the brake linings wear. However, an unexpected drop in fluid level may be caused by a leak and a system check should be conducted. Only brake fluid conforming to MVSS DOT 3 and SAE J1703 should be used. Mopar brake fluid is of this quality and is recommended to provide best brake performance. WARNING! Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident. Use only brake fluid that has been in a tightly closed container to avoid contamination from foreign matter or moisture. CAUTION! Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications Clutch Fluid: Capacity Specifications HYDRAULIC - FLUID CAUTION: Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system. NOTE: The clutch hydraulic system and replacement components are pre-filled, and under normal operating conditions, additional fluid is not required for the life of the vehicle. The fluid required for use in the clutch hydraulic system is brake fluid conforming to DOT 3 specifications and J1703 standards. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Capacity Specifications > Page 1199 Clutch Fluid: Fluid Type Specifications The clutch hydraulic system is a sealed maintenance free system. In the event of leakage or other malfunction, the system must be replaced. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications > Page 1200 Clutch Fluid: Testing and Inspection CLUTCH CONTAMINATION Fluid contamination is a frequent cause of clutch malfunctions. Oil, water or clutch fluid on the clutch disc and pressure plate surfaces will cause chatter, slip and grab. During inspection, note if any components are contaminated with oil, hydraulic fluid or water/road splash. Oil contamination indicates a leak at either the rear main seal or transmission input shaft. Oil leakage produces a residue of oil on the housing interior and on the clutch cover and flywheel. Heat buildup caused by slippage between the cover, disc and flywheel, can sometimes bake the oil residue onto the components. The glaze-like residue ranges in color from amber to black. Road splash contamination means dirt/water is entering the clutch housing due to loose bolts, housing cracks or through hydraulic line openings. Driving through deep water puddles can force water/road splash into the housing through such openings. Clutch fluid leaks are usually from damaged slave cylinder push rod seals. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .......................................... 15.5 Liters ( 16.3 qts ) Note: Includes 0.9 Liters ( 1.0 qts ) for coolant reservoir. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1205 Coolant: Fluid Type Specifications Coolant Types This vehicle has been factory filled with an Ethylene Glycol-based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). When it becomes necessary to replace the coolant, use a coolant like Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula, P/N 5011764AB or equivalent. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37 °C (-35 ° F). Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1206 Coolant: Service Precautions CAUTION: Mixing of coolants other than specified (non-HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. If a non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Do not use plain water alone or alcohol base antifreeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propylene Glycol based coolants is not recommended. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant DESCRIPTION - ENGINE COOLANT ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 year/100,00OMile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. Dodge Ram 1500 4wd Workshop Manual (Truck V8-5.9L VIN Z (2002)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant > Page 1209 Coolant: Description and Operation Hoat Coolant DESCRIPTION - HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water.