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2006-2008--Chrysler--300--6 Cylinders R 2.7L MFI DOHC--33238801
Dodge - Voyager - Workshop Manual - 2006 - 2008
Chrysler - Sebring - Wiring Diagram - 2009 - 2009
2004 Chrysler Crossfire Technical Publications
1999-2006--Chrysler--Sebring--4 Cylinders Y 2.0L FI DOHC--32537002
Chrysler - PT Cruiser - Owners Manual - (2003)
1996-1999 Chrysler Voyager GS Service Repair Manual PDF
Chyrsler - Grand Voyager - Workshop Manual - 1998 - 1998
Chrysler - 300 - Wiring Diagram - 2005 - 2005
Dodge Daytona Iroc Workshop Manual (V6-181 3.0L SOHC VIN 3 FI (1992))
1999-2005--Chrysler--Sebring--6 Cylinders T 2.7L MFI FFV DOHC--32997703
2006-2008--Chrysler--Pacifica AWD--6 Cylinders 4 3.5L FI SOHC--33029501
2006-2008--Chrysler--300C--8 Cylinders H 5.7L FI OHV Hemi--33132701
1997 JX Sebring Stratus Convertible (RHD & LHD) Interactive Electronic Service Manual
Grand Voyager L4-153 2.5L SOHC Turbo (1990)
Dodge Daytona Workshop Manual (L4-153 2.5L SOHC (1987))
Chrysler - Aspen - Workshop Manual - 2005 - 2005
2006--Chrysler--Sebring--4 Cylinders X 2.4L FI DOHC--33030401
2006-2008--Chrysler--300C--8 Cylinders W 6.1L FI OHV Hemi--33132702
2003-2005--Chrysler--Pacifica 2WD--6 Cylinders 4 3.5L FI SOHC--32912601
Chrysler - Auto - chrysler-300-2012-owner-s-manual-srt-78947
Dodge Daytona Workshop Manual (V6-181 3.0L SOHC VIN 3 FI (1993))
Chrysler - Neon - Workshop Manual - (2004)
Chrysler - Town and Country - Owners Manual - (2005)
Chrysler - Town and Country - Miscellaneous Documents - 2008 - 2016
2005--Chrysler--300--6 Cylinders G 3.5L FI SOHC HO--32969104
2006-2008--Chrysler--Pacifica 2WD--6 Cylinders 4 3.5L FI SOHC--33029401
2000-2004--Chrysler--Voyager--6 Cylinders 3 3.3L MFI FFV OHV--32860302
1997 JA Cirrus Stratus (RHD & LHD) Interactive Electronic Service Manual PDF
Dodge Daytona Pacifica Workshop Manual (L4-135 2.2L SOHC Turbo VIN E FI (1988))
1995-1998--Chrysler--Sebring Convertible--6 Cylinders H 2.5L FI SOHC--32339802
Chrysler - Sebring - Owners Manual - 2007 - 2008
2007--Chrysler--Aspen 4WD--8 Cylinders N 4.7L FI SOHC--33115303
Chyrsler - Pacifica - Workshop Manual - 2017 - 2017
Chrysler - Auto - chrysler-300c-2013-manual-del-propietario-82040
2006-2008--Chrysler--300 AWD--6 Cylinders G 3.5L FI SOHC HO--33132601
2006-2008--Chrysler--Crossfire--6 Cylinders L 3.2L MFI SOHC--33265401
Chrysler - 300c Srt8 - Owners Manual - 2006 - 2006
Chrysler - Sebring Convertible - Owners Manual - 2006 - 2009
2004-2005--Chrysler--Crossfire--6 Cylinders L 3.2L MFI SOHC--32912201
Voyager L4-153 2.5L SOHC (1990)
1998-2004--Chrysler--300M--6 Cylinders G 3.5L FI SOHC HO--32912101
Chrysler - Viper - Workshop Manual - 1999 - 1999
Chrysler - Auto - chrysler-300c-2013-manual-del-propietario-82040_5d8a7f89b31387a04326477
Chrysler - 300 - Workshop Manual - 2006 - 2008
Chrysler - Town and Country - Owners Manual - (2007)
2003-2005--Chrysler--Pacifica 2WD--6 Cylinders L 3.8L FI OHV--32978202
Chyrsler - Stratus - Sales Brochure - 1995 - 1995
Chrysler - Town and Country - Owners Manual - (2008)
1995-1998--Chrysler--Sebring--6 Cylinders 2.5L MFI--31980502
Chrysler - 300 - Workshop Manual - (2013)
Chyrsler - Sebring - Owners Manual - 2010 - 2010 (2)
Chyrsler - Crossfire - Owners Manual - 2005 - 2005
2007--Chrysler--Aspen 4WD--8 Cylinders 2 5.7L FI OHV Hemi--33115302
Chrysler - Auto - chrysler-300c-2009-owner-s-manual-72820
Chrysler - Town and Country - Owners Manual - (2014)
Chyrsler - Pacifica - Owners Manual - 2005 - 2005
2000-2004--Chrysler--Grand Voyager 2WD--6 Cylinders R 3.3L FI OHV--32657502
Chrysler - Auto - chrysler-sebring-2004-owner-s-manual-78998
Chrysler - Pacifica - Owners manual - 2006 - 2007
Summary of Content
Page 877 Throttle Position Sensor: Testing and Inspection TPS / IAC Motor Location The throttle position sensor (TPS) can be tested with a digital voltmeter. The sensor must be checked on the vehicle with its three wire connector engaged to the sensor. The center terminal wire of the sensor connector is the output terminal. 1. Remove the air filter housing assembly. 2. Carefully attach a paper clip into the center terminal of the sensor harness. 3. Attach the positive (+) lead of the voltmeter to this paper clip. 4. Attach the negative (-) lead of the voltmeter to a good ground. With the ignition key in the ON position and engine not running, check the sensor output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, sensor output voltage should be greater than 200 millivolts. At wide open throttle, sensor output voltage must be less than 4.8 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Page 479 ALPHABETICAL INDEX (Part 5 Of 6) Page 713 Radio And Sensor Ground Page 650 PCM System Schematic System Diagram For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Body Control Module For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Camshaft Position Sensor For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Page 1200 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Page 875 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle. 2. Remove front wheels. 3. Remove disc brake caliper and support to frame using suitable wire. 4. Remove bolts attaching sensor to splash shield and steering knuckle. Retain special sensor bolts for installation. 5. Remove wire clamps and wire from control arm and steering knuckle. 6. Disconnect sensor harness connector and work sensor wire through fender panel, then remove sensor from vehicle. 7. Reverse procedure to install, noting the following: a. Torque special sensor bolt to 16-21 ft. lbs. Locations ABS Main Relay: Locations Power Distribution Center Power Distribution Center Page 531 Overhead Console (Part 2 Of 2) Page 559 Rear Lighting (Part 1 Of 2) Page 75 Power Distribution Center Page 185 195 Page 450 Headlamp Switch Connector Specifications Camshaft Position Sensor: Specifications Torque ................................................................................................................................................. ........................................................ 6 Nm (50 in. lb) Page 708 Vacuum Control System Vacuum Schematic Page 915 8D - 36 Page 576 Joint Connector(B) Page 716 Fig.3 Roof Wiring Splices Page 429 84-way Connector Instrument Panel To Headlamp And Dash Wiring (Part 2 Of 2) With Four Wheel Antilock System Electronic Brake Control Module: Service and Repair With Four Wheel Antilock System Fig. 25 Main Harness Connector NOTE: The ABS module is located in the engine compartment attached to the forward side of the front brake anti-lock valve. 1. Disconnect upper harness connector from module. 2. Lift connector locking handle to release main harness connector for module. Rotate handle upward to clear connector. 3. Lift connector up and out of retaining lugs on module. 4. Remove module mounting screws then the module. 5. Reverse procedure to install, installing harness main connector as follows: a. Connecting main harness connector to module. b. Seat connector in module retaining lugs and start connector into module. c. Rotate connector locking handle downward into position to seat and retain connector. Page 190 256 Page 454 Multi-Function Switch Connector Page 491 Transmission Overdrive System (Part 3 Of 3) Page 313 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 ADDITIONAL INFORMATION If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter SAFETY RECALL TO REPLACE YOUR TRUCK'S HEADLAMP SWITCH AND INSTALL A RELAY WIRING HARNESS Dear Dodge Ram 3500 Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1994 through 1997 Dodge Ram 3500 Series trucks. The problem is... Driving your Ram truck (identified on the enclosed form) with the lights on for an extended time frame can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. What DaimlerChrysler and your dealer will do... Daimlerchrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the headlamp switch and do install a relay wiring harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your saftey... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call l-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. RAY Radio - Loss of Sound From Right Speakers Speaker: All Technical Service Bulletins RAY Radio - Loss of Sound From Right Speakers NO: 08-06-94 GROUP: Electrical DATE: Feb. 4, 1994 SUBJECT: RAY Radio Looses Right Side Speakers MODELS: 1994 (BR) Ram Truck DISCUSSION: The Infinity sound system with a RAY radio (cassette with equalizer), P/N 5269463, may experience a loss of sound from the right speakers when power seats or other electrical devises are activated. The speakers will generally return when the radio is turned off, then back on, or when a station button is depressed. This condition is not present with the RAS radio. If complaints are received, contact your local Huntsville Repair Center. They can arrange to exchange the radio for a revised unit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 08-60-02-95 0.3 Hrs. FAILURE CODE: 58 - Internal Defect Page 679 Intermittent Wiper System (Part 2 Of 2) Drive Belt Page 929 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Page 757 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Location REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting bolt. 4. Using two small screwdrivers, carefully pry sensor from timing chain cover. 5. Remove sensor from vehicle. 6. Inspect condition of o-ring. INSTALLATION (New Sensor) 1. Apply a small amount of clean motor oil to sensor o-ring. 2. Install the sensor into the timing cover with a slight rocking motion. Push the sensor all the way into the cover until the rib material on the sensor contacts the cam gear. 3. Install sensor mounting bolt and torque to 6 Nm (50 in-lbs). 4. Connect sensor electrical connector. Camshaft Position Sensor Installation Page 114 Fuel Pump Relay: Testing and Inspection Relay Terminals The relay terminal numbers can be found on the bottom of the relay. - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Page 799 Engine Wiring Connector Locations Page 779 Crankshaft Position Sensor: Testing and Inspection Sensor Connector 1. Disconnect the sensor pigtail harness from the main engine wiring harness connector. 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Page 461 Powertrain Control Module Page 1126 8. Install the bolt and torque it to 312 Nm (230 ft. lbs.). NOTE: USE A BAR TO LOCK THE PULLEY IN PLACE WHILE TIGHTENING. 9. Install a new accessory drive belt following service manual procedures. 10. Reinstall the radiator following service manual procedures. 11. Reinstall the negative battery cable. 12. Fill the cooling system with the saved coolant and operate the vehicle to purge air from the system. Top off the automatic transmission fluid (if required). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-25-25-90 1.5 Hrs. FAILURE CODE: P8 - New Part Page 869 Throttle Position Sensor: Locations TPS / IAC Motor Location The throttle position sensor is mounted on throttle body. Page 558 Seatbelt Warning And Buzzer System (Part 2 Of 2) Page 712 Fig.14 Ground Identification Page 606 Headlamp Switch And Joint Connector(A) Wiring (Part 2 Of 2) Page 710 Vacuum Control System Fuse Panel Location The fuse block is located directly below the steering column, behind the lower steering column cover. The hazard flasher and turn signal flasher plug directly into the fuse block. The fuse block may be accessed by removing knee blocker panel beneath steering column. Power Distribution Center Page 771 Crankshaft Position Sensor: Locations Crankshaft Position Sensor Location The Crankshaft Position Sensor is mounted on the right side of engine block, behind the exhaust manifold. Page 732 Fig.9 Engine Compartment Wiring (Part 1 Of 4) Page 1098 Spark Plug: Testing and Inspection Normal Operating Conditions Normal Operation And Carbon Fouling 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 (.001 in) per 1600 km (1000 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 is not affected by MMT deposits. Page 903 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 663 Charging System Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 658 Seatbelt Warning And Chime System (Bux Only) (Part 1 Of 2) Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 293 3. To remove the "blue" wedge insert a small screwdriver between the top of the wiring connector insulator and the wedge and prying up while pushing the wedge out towards the wire harness, Figure 2. 4. To reinstall the wiring harness connector into the stop light switch, reinstall the connector wedge into the connector, then insert the wiring harness connector into the stop light switch assembly and finally install the stop lamp switch assembly into the mounting bracket and secure it by rotating the switch clockwise approximately 1/16 of a turn. If a new stop light switch is being installed, follow the adjustment procedure in the appropriate service manual. POLICY: Information Only Page 95 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications Vacuum in Inches of Mercury MAP sensor Signal Voltage .39 in Hg 4.90 V .............................................................................................................................................................. .............. 3.34 in Hg 4.60 V .............................................................................................................................................................. ............. 6.30 in Hg 3.60 V .............................................................................................................................................................. ............. 9.25 in Hg 3.10 V .............................................................................................................................................................. ............. 12.20 in Hg 2.60 V .............................................................................................................................................................. ............ 15.15 in Hg 2.10 V .............................................................................................................................................................. ............ 18.11 in Hg 1.60 V .............................................................................................................................................................. ............ 21.06 in Hg 1.10 V .............................................................................................................................................................. ............ 24.01 in Hg 0.60 V .............................................................................................................................................................. ........... 26.97 in Hg 0.31 V .............................................................................................................................................................. ........... Page 21 Related Images Page 528 Cargo And Dome Lamps Page 774 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 626 Stop/Turn And Hazard Flasher System Page 56 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 917 8D - 38 Page 737 Fig.14 Transmission Wiring (Automatic) Specifications Alignment Specifications Page 824 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 694 During Full Throttle 3-2 Downshift (Passing Gear) Page 778 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Location PURPOSE The signal from the Crankshaft Position (CKP) Sensor is used to determine crankshaft angle, engine speed, and basic timing. Powertrain Control Module (PCM) also uses the signal from the crankshaft position sensor combined with the input signal from the camshaft position sensor to properly synchronize fuel injection. OPERATION The crankshaft position sensor is a hall effect switch that detect notches on a pulse ring mounted to the crankshaft. The notches cause a pulse to be generated when they pass under the sensor. The pulses are input to the PCM. For each engine revolution there are 5 groups of 2 pulses generated. Crankshaft position is determined during cranking. Once the last slot of a set has been detected, crankshaft position can be determined by combining crankshaft and camshaft position input. This process may take up to one complete crankshaft revolution. If the PCM does not sense input from the crankshaft position sensor, PCM will deactivate the automatic shutdown relay and fuel pump relay, interrupting voltage to fuel pump, fuel injectors, and ignition coil, (no start condition). Locations Fig.12 Fuse Block And Relay Bank Page 440 Fender And Tailgate Lamps (Dual Rear Wheels) Page 134 Ignition Control Module: Service and Repair ICM Location 1. Disconnect negative battery cable. 2. Remove coolant overflow/recovery tank. 3. Remove electrical connector from Ignition Control Module (ICM). 4. Remove ICM mounting screws. 5. Reverse procedure for installation. Page 1019 Idle Speed: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are visible. Perform Minimum Idle Air Flow Test if applicable. Page 426 84-way Connector Headlamp And Dash To Instrument Panel Wiring (Part 1 Of 2) Page 566 Fuseblock (Part 2 Of 2) Page 635 Power Mirror System (Part 1 Of 2) Page 633 Underhood Lamp Page 861 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 176 69 Page 519 Front End Lighting With Daytime Running Lamps (Part 2 Of 2) Page 132 Ignition Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 1076 14. Install the screw attaching the trim panel to the outside mirror frame. 15. Install the window crank, if equipped. 16. Perform Steps 3 through 1 5 to the other door trim panel. 17. Connect the battery negative cable(s) and reset the clock. 18. Roll the windows up. 1-WINDOW CRANK REMOVAL TOOL 2-WINDOW CRANK Figure 1 1-POWER MIRROR 2-SCREW 3-POWER MORROR CONTROL 4-SCREW 5-TRIM PANEL 6-DOOR LOCK BUTTON 7-POWER WINDOW HARNESS 8-POWER MIRRIR HARNESS Figure 2 Replacement Notes Spark Plug: Service and Repair Replacement Notes TIP: Always keep plugs in the order they were removed. Any plug that looks different from other plugs indicates a problem in that cylinder. NOTE: For further diagnosis by spark plug condition SEE Ignition System/Spark Plug/Testing and Inspection/Procedures Page 332 3. Remove the cup holder assembly from the instrument panel. 4. Remove the ash receiver from the ash receiver bracket. Fig. 2 5. Remove the two (2) screws that secure the ash receiver bracket to the instrument panel. 6. Remove the ash receiver bracket from the instrument panel. Fig. 3 7. Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers. 8. Unplug the wiring harness connector from the lighter. 9. Unplug the wiring harness connector from the auxiliary power outlet. 10. Set the cluster bezel aside. Fig. 4 11. Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel. 12. Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s). Page 916 8D - 37 Page 651 Diagrams Crankshaft Position Sensor For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Engine Control Module For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Oxygen Sensor For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Throttle Position Sensor For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Vehicle Speed Sensor For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Emission Control Systems For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Page 649 Fuel Injection Ignition System (Part 10 Of 10) Locations High Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. Page 133 Ignition Control Module: Description and Operation ICM Location PURPOSE The Ignition Control Module (ICM) assists the Powertrain Control Module (PCM) by operating the ignition coils that fire cylinders 4/7 and 5/10. The ICM responds to commands from the PCM and controls ignition coil dwell and ignition timing. OPERATION The PCM and ICM do not communicate directly. The PCM receives vehicle speed input directly and transmits dwell data to the ICM. The PCM receives both crankshaft and camshaft position directly. The PCM supplies an 8 Volt referance signal to the crankshaft, camshaft position sensor, and ICM. Page 596 Anti-Lock Brake System (Part 2 Of 4) Page 521 Underhood Lamp Page 935 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Page 1175 Air Injection Filter: Service and Repair Air Pump Air Filter NOTE: The air injection pump air filter is a non-repairable unit. Do not attempt to clean or replace filter within housing. Replace the entire filter/filter housing assembly. REMOVAL 1. Remove the silencer tube from filter housing. 2. Remove the inlet tube from filter housing. 3. Remove the rubber cap from filter housing. 4. Remove the filter housing mounting strap bolt. 5. Note position of housing, and remove housing from the bracket. INSTALLATION 1. Position filter housing in mounting bracket. 2. Install and tighten mounting strap bolt. 3. Install the rubber cap on filter housing. 4. Install the inlet tube on filter housing. 5. Install the silencer tube on filter housing. Specifications Powertrain Control Module: Specifications Mounting Screw Torque ...................................................................................................................... ....................................................... 1 Nm (9 in. lb.) Connector Screw Torque ..................................................................................................................... ..................................................... 4 Nm (35 in. lb.) Page 800 Manifold Pressure/Vacuum Sensor: Description and Operation MAP Sensor Output Characteristic PURPOSE The Manifold Absolute Pressure (MAP) sensor is used to monitor intake manifold pressure (engine load). It sends voltage signals to the Powertrain Control Module (PCM) that represent the engines varying load conditions. THEORY/OPERATION The PCM supplies 5 volt sensor reference voltage. The sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. Changes in manifold absolute pressure are sensed by a silicon crystal in the MAP sensor. This crystal changes the resistance of the sensor depending upon the manifold absolute pressure acting upon it, and the change in resistance affects the amount of voltage that the sensor allows to flow back to the PCM. Manifold absolute pressure and voltage to PCM are directly proportional (manifold absolute pressure increases, low vacuum, voltage to PCM increases and vice versa). Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). TYPICAL READINGS Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum (low pressure) situation, such as idle or deceleration. Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum (pressure) such as a cruise or slight acceleration condition. Output voltages between 3.0 and 4.5 volts indicate a low vacuum (high pressure) situation such as hard acceleration or a mechanical failure. Any reading of 0 volts or over 4.5 volts indicates a problem. Page 872 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Fuel Gauge - Sticks at Full Intermittently Fuel Gauge Sender: Customer Interest Fuel Gauge - Sticks at Full Intermittently NO: 08-10-94 GROUP: Electrical DATE: Feb. 18, 1994 SUBJECT: Fuel Gauge Sticks MODELS: 1994 (BR) Ram Truck SYMPTOM/CONDITION: The fuel gauge may intermittently stick at full with less than a full tank of fuel. PARTS REQUIRED: 1 52127747 Pump Module (26 and 35 gal. 3.9L, 5.2L, 5.9L) 1 52127748 Pump Module (35 gal 5.9L HD, sales code EMM) 1 52127749 Pump Module (35 gal. 5.9L Diesel, sales code ETB) REPAIR PROCEDURE: This bulletin involves replacing the fuel pump module. Using the procedures outlined in the 1994 Ram Truck Service Manual, Publication Number 81-370-4108, page 14-4, replace the fuel pump module with the appropriate part listed in the Parts Required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.14-50-02-90.......1.3 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Page 473 Power Window System -- Part 2 Page 403 Spark Plug Wire - Engine Miss and /or Rough Idle Ignition Cable: All Technical Service Bulletins Spark Plug Wire - Engine Miss and /or Rough Idle NO: 18-09-95A GROUP: Vehicle Performance DATE: April 21, 1995 SUBJECT: Engine Miss and/or Rough Idle MODELS: 1994 - 1995 (BR) Ram Pickup THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-09-95 DATED MARCH 10, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. Note: This Bulletin Applies To Vehicles Equipped With An 8.0L V10 Engine Built Prior to 2/14/94 (MDH 02-14-XX). SYMPTOM/CONDITION: Engine miss and/or rough idle may be experienced. The cause of the engine miss and/or rough idle may be the secondary ignition cables shorting at the coil boot. DIAGNOSIS: This condition will normally show NO fault codes. It may mislead the technician into diagnosing this problem as being related to a base engine component malfunction, such as stuck lifters or valve train problems. If the vehicle is brought in for service with vehicle performance complaints (rough idle, engine miss), and the DRB does not show any fault codes, check ignition cables for the date code of 1st quarter 1994 (1-94) or earlier. The date code will appear as follows: Note: Date coding is done quarterly on wires. example is given below. MOPAR ELECTRONIC SUPPRESSION GX 1-94 AATH GX = Material Code 1-94 = Date Code - Represents the 1st Quarter of 1994 AATH = Vendor Identification **Note: If the ignition cables are found to be dated the first quarter of 1994 (1/94) or earlier, they should be replaced with cables dated 2nd quarter (2/94) and later.** POLICY: Information Only Page 862 Vehicle Speed Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 676 Power Window System -- Part 1 Locations Page 507 Rear Wheel ABS System (Part 2 Of 2) Page 518 Front End Lighting With Daytime Running Lamps (Part 1 Of 2) Page 259 Low Pressure Sensor / Switch: Description and Operation Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Page 472 Power Window System -- Part 1 Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 607 Joint Connector(B) Wiring Page 541 Infinity Stereo Radio System (Part 1 Of 2) Service and Repair Clutch Linkage: Service and Repair NOTE: The clutch master cylinder, remote reservoir, slave cylinder and connecting lines are all serviced as an assembly. These components cannot be serviced separately. The linkage cylinders and connecting lines are sealed units. They are pre-filled with fluid during manufacture and must not be disassembled nor disconnected. REMOVAL 1. Raise and support vehicle. 2. On diesel models, remove slave cylinder shield from clutch housing, if equipped. 3. Remove nuts attaching slave cylinder to studs on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Disengage slave cylinder fluid line from body retainer clips. 6. Lower vehicle. 7. Disconnect clutch pedal interlock switch wires. 8. Remove locating clip from clutch master cylinder mounting bracket. 9. Remove retaining clip, flat washer and wave washer that attach clutch master cylinder push rod to clutch pedal. 10. Slide clutch master cylinder push rod off pedal pinch 11. Inspect condition of bushing on clutch pedal pin. Remove and replace bushing if worn or damaged. 12. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 13. Remove screws that attach clutch fluid reservoir to dash panel. 14. Remove reservoir mounting bracket screws and remove reservoir from dash panel. 15. Rotate clutch master cylinder 45° counterclockwise to unlock it. Then remove cylinder from dash panel. Page 829 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) PURPOSE This vehicle uses two oxygen sensors. The Powertrain Control Module (PCM) uses these signals to fine tune air/fuel mixture for each cylinder bank. This is done by varying injector pulse width (ON time). OPERATION The oxygen sensor is a voltage generating device. A voltage signal (0-1 volt) is generated by comparing the difference in oxygen content between the exhaust gases and outside air. The higher the difference (rich mixture, low exhaust oxygen content) the higher the voltage generated by the oxygen sensor. Smaller differences (lean mixture, high exhaust oxygen content) result in a lower voltage being generated. On this engine, pairs of injectors are fired (five pairs with one injector on each cylinder bank). Because of this, the PCM is not able to separately adjust left and right bank fuel injection. The PCM averages reading from both O2 sensors, and injects fuel at a common rate for all ten cylinders. The oxygen sensor has a heating element that maintains proper oxygen sensor operating temperature at all times. This process allows the vehicle to enter closed loop at an earlier time and to remain in closed loop during the remainder of the operating cycle. The oxygen sensor heating element receives voltage from the fuel pump relay. During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. Page 101 Powertrain Control Module: Description and Operation Modes of Operation Acceleration Mode This is a OPEN LOOP mode. - The Powertrain Control Module (PCM) recognizes an abrupt increase in throttle position or MAP pressure, as a demand for increased engine output to accelerate vehicle. - The PCM increases injector pulse width, in response to increased fuel demand. Cruise Mode This is a CLOSED LOOP mode. With engine at operating temperature, the Powertrain Control Module (PCM) receives inputs from: - Air Conditioning Control Position - Battery voltage - Camshaft position (CMP) sensor - Engine coolant temperature (ECT) sensor - Manifold absolute pressure (MAP) sensor - Intake air temperature (IAT) sensor - Crankshaft position (CKP) sensor - Throttle position sensor (TPS) Heated oxygen sensor (HO2S) Based on these inputs the PCM will: - Apply voltage to the injectors. The PCM then controls injection sequence and pulse width by switching individual injector ground paths on and off. - Monitor oxygen sensors and fine tune air/fuel ratio by varying injector pulse width. - Adjust engine idle speed through the IAC motor. - Adjust ignition timing. - Operate A/C Compressor Clutch relay (if selected). Deceleration Mode This is an OPEN LOOP mode. During deceleration the the Powertrain Control Module (PCM) receives inputs from: - Air Conditioning Control Position - Battery voltage - Camshaft position (CMP) sensor - Engine coolant temperature (ECT) sensor - Manifold Absolute Pressure (MAP) sensor - Intake air temperature (IAT) sensor - Crankshaft position (CKP) sensor - Throttle Position Sensor (TPS) Based on these inputs the PCM will: - Adjust engine idle speed through the IAC motor. - Adjust ignition timing. - Operate A/C Compressor Clutch relay (if selected). - Ignore oxygen sensor input. The PCM will enter fuel cut-off strategy (under hard deceleration). - Determine proper injector pulse width and continue injection (under normal deceleration). Engine Start-Up Mode This is an OPEN LOOP mode. When the starter motor is engaged, the Powertrain Control Module (PCM) receives input from: - Battery voltage - Crankshaft position (CKP) sensor - Engine coolant temperature (ECT) sensor Intake air temperature (IAT) sensor - Throttle position sensor (TPS) - Camshaft position (CMP) sensor - Starter relay Page 406 Body Connector Page 847 Throttle Position Sensor: Adjustments PROCEDURE ^ The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. ^ If sensor output voltage is outside acceptable range, sensor should be replaced. Page 337 3. Install the switch knob and shaft on the new switch assembly by depressing the release button on the bottom of the switch assembly and then inserting the shaft into the switch assembly. Fig. 10 4. Connect the 9-way wiring connector to the headlamp switch. Fig. 10 5. Connect the 2-way wiring connector to the headlamp switch (if equipped). Fig. 10 Page 505 Airbag System (Part 2 Of 2) Page 372 Page 73 Power Distribution Center Page 776 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 312 Fig. 1 13. Install the cup holder assembly. Tighten the cup holder screws securely. 14. Connect the negative battery cable(s). COMPLETION REPORTING AND REIMBURSEMENT Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerClrrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace headlamp switch and 08819182 0.5 hours install overlay harness Replace headlamp switch, install 08819183 0.9 hours overlay harness and replace 4 wires Replace headlamp switch, install 08819184 1.1 hours overlay harness and replace 5-9 wires Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions PARTS RETURN Not required. DEALER NOTIFICATION AND VEHICLE LIST All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL SYSTEM FUNCTIONS 53 AND VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD819". OWNER NOTIFICATION AND SERVICE SCHEDULING All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. VEHICLE NOT AVAIABLE If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Page 889 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 452 Headlamp Switch And Joint Connector(A) Wiring (Part 2 Of 2) Page 469 Trailer Tow System And Ground Joint (Part 1 Of 2) Page 821 Oxygen Sensor Location Page 220 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 253 High Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Page 552 Power Mirror System (Part 2 Of 2) Page 1099 Spark Plug: Testing and Inspection Chipped Electrode or 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. Cold Fouling/Carbon Fouling Normal Operation And 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 filter or repeated short operating times (short trips). Electrode Gap Bridging Spark Plug Inspection ^ 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, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Normal Operating Conditions Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications Temperature VS. Voltage Curve NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V Page 334 Fig. 7 ^ Carefully inspect the connector and terminals B1, B2, R and H for signs of damage from overheating (melted connector and/or discolored terminal). If any one of these terminals shows signs of damage, ALL FOUR of these terminals MUST be replaced. Continue with Step 3. ^ Carefully inspect the connector and all other terminals. If any terminals in addition to B1, B2, R and H are damaged, terminals B1, B2, R, H and any other damaged terminals MUST be replaced. Continue with Step 3. ^ If there is no indication of heat damage, continue with Step 6. 3. For vehicles with headlamp switch wire terminal and connector heat damage: Remove any damaged wire terminals from the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent. If the connector is also damaged and cannot be reused, remove all wires and discard the connector. 4. Replace any damaged wires as determined in Step 2 as follows: a. Cut the electrical tape and remove the affected wire(s) from the bundle. b. Cut off the damaged wire approximately 10 inches from the terminal. NOTE: Stagger the wire splice locations by about 1/2 inch. c. Remove about 1 inch of insulation from the end of the wire. d. Remove about l inch of insulation from the end of the matching color and gauge wire and terminal provided in the parts package. e. Slip one piece of the provided heat shrink tubing over the new wire end. f. Twist the exposed wire ends of the harness wire and the replacement wire end together. g. Solder the twisted wire ends together using rosin core solder. CAUTION: All wiring splices must be soldered or future circuit failure may occur. h. Slide the heat shrink tubing over the wire splice and heat the tubing until the tubing shrinks tightly around the wire and sealant comes out both ends of the tubing. i. Repeat Steps A - H for all other damaged wires as necessary. Page 419 Right Door Connector (Part 1 Of 2) Page 126 ICM Location Page 637 Engine Oil Pressure And Engine Coolant Temp. System Page 189 209 Page 845 Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation PURPOSE This sensor is used to send input signals to the Powertrain Control Module (PCM) to indicate the current angle of the throttle blade. THEORY/OPERATION This sensor is a variable resistor that has a 5 volt reference signal applied to it by the PCM. The Throttle Position Sensor (TPS) sends signals back to the PCM in the range of approximately 1 to 4 volts, depending upon the throttle shaft angle. The PCM uses these input voltages to determine the current position of the throttle. The PCM uses the voltage signals from the TPS and other input sensors to determine the proper air/fuel mixture and ignition timing for certain operating conditions. Some of these operating conditions are: acceleration, deceleration, idle, and wide open throttle. TYPICAL READINGS An input voltage of approximately 1 volt indicates a minimum throttle opening, idle, or deceleration condition. An input voltage of approximately 2 volts indicates a cruise or light acceleration condition. An input voltage of approximately 4 volts would indicate a maximum throttle opening or wide open throttle condition. Page 674 Transmission Overdrive System (Part 2 Of 3) Page 996 Wiper Switch: Service and Repair Multi-Function Switch 1. Disconnect battery ground cable. 2. On models equipped with tilt wheel, remove tilt lever. 3. Remove knee blocker. 4. Remove upper and lower column covers. 5. Move upper fixed column shroud to gain access to rear of multi-function switch. 6. Remove multi-function switch tamper proof attaching screws. 7. Remove switch from column, loosen connector screw, then remove wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque all retaining screws to 17 in-lbs. b. Torque steering column upper bracket nuts to 9-10 ft-lbs. Page 145 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Page 595 Anti-Lock Brake System (Part 1 Of 4) Page 827 Oxygen Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 655 Stereo Radio System (Part 2 Of 2) Page 765 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Sensor Location The engine coolant temperature sensor threads into intake manifold, next to the thermostat housing. Page 120 Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Terminals The relay terminal numbers can be found on the bottom of the relay. - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Page 573 Engine Connector-B Page 489 Transmission Overdrive System (Part 1 Of 3) Ignition Cable - Engine Miss and/or Rough Idle Ignition Cable: All Technical Service Bulletins Ignition Cable - Engine Miss and/or Rough Idle NO: 18-09-95 Rev. A GROUP: Vehicle Performance DATE: Apr. 21, 1995 SUBJECT: Engine Miss and/or Rough Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-09-95 DATED MAR. 10, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994-1995 (BR) Ram Pickup NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L V10 ENGINE BUILT PRIOR TO 2/14/94 (MDH 02-14-XX). SYMPTOM/CONDITION: Engine miss and/or rough idle may be experienced. The cause of the engine miss and/or rough idle may be the secondary ignition cables shorting at the coil boot. DIAGNOSIS: This condition will normally show NO fault codes. It may mislead the technician into diagnosing this problem as being related to a base engine component malfunction, such as stuck lifters or valve train problems. It the vehicle is brought in for service with vehicle performance complaints (rough idle, engine miss), and the ORB scantool does not show any fault codes, check ignition cables for the date code of 1st quarter 1994 (1-94) or earlier. The date code will appear as follows: NOTE: DATE CODING IS DONE QUARTERLY ON WIRES. EXAMPLE IS GIVEN BELOW. MOPAR ELECTRONIC SUPPRESSION GX 1-94 AATH GX = Material Code 1-94 = Date Code - Represents the 1st Quarter of 1994 AATH = Vendor Identification **NOTE: IF THE IGNITION CABLES ARE FOUND TO BE DATED THE FIRST QUARTER OF 1994 (1/94) OR EARLIER, THEY SHOULD BE REPLACED WITH CABLES DATED 2ND QUARTER (2/94) AND LATER**. POLICY: information Only Recall 99V024000: Possible Headlamp Switch Failure Headlight Switch: Recalls Recall 99V024000: Possible Headlamp Switch Failure Operation of the headlamps over an extended period of time can result in Headlamp switch failure, causing the headlamps or park lamps to go out. If the lights fail, a visibility problem could occur, increasing the risk of a vehicle crash. Dealers will replace the Headlamp switch including a relay in the park lamp wiring circuit. Owner notification began June 14, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 906 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor Location PURPOSE The signal from the Crankshaft Position (CKP) Sensor is used to determine crankshaft angle, engine speed, and basic timing. Powertrain Control Module (PCM) also uses the signal from the crankshaft position sensor combined with the input signal from the camshaft position sensor to properly synchronize fuel injection. OPERATION The crankshaft position sensor is a hall effect switch that detect notches on a pulse ring mounted to the crankshaft. The notches cause a pulse to be generated when they pass under the sensor. The pulses are input to the PCM. For each engine revolution there are 5 groups of 2 pulses generated. Crankshaft position is determined during cranking. Once the last slot of a set has been detected, crankshaft position can be determined by combining crankshaft and camshaft position input. This process may take up to one complete crankshaft revolution. If the PCM does not sense input from the crankshaft position sensor, PCM will deactivate the automatic shutdown relay and fuel pump relay, interrupting voltage to fuel pump, fuel injectors, and ignition coil, (no start condition). Page 591 Page 951 Clutch Switch: Service and Repair The clutch start switch is an integral part of the clutch master cylinder pushrod and cannot be serviced separately. Page 434 Rear Lighting (Part 1 Of 2) Page 905 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 471 Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Page 1084 Ignition Cable: Testing and Inspection Ignition Wire Inspection 1. Visually inspect the ignition wires for the following: a. Insulation for swelling or breakdown due to fuel, oil, grease or etc. b. Insulation for cracks or breaks. c. Insulator boots for swelling or breakdown due to fuel, oil, grease or etc. d. Insulator boots for cracks or breaks. e. Terminal ends for corrosion, cracks or looseness. Ignition Wire Resistance Test 2. Using an ohmmeter, check the resistance between the terminal ends. Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Page 575 Joint Connector(A) Page 754 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 397 Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement The content of this article reflects changes called for in TSB 26-01-97. Fig 42 Recirculating Air Door Actuator REMOVAL 1. Remove the glove box from the instrument panel. 2. Disconnect the vacuum line from the actuator. 3. Reaching through the access hole in the back of the glove box opening in the instrument panel, loosen the two nuts that secure the actuator mounting studs to the mounting bracket on the heater-A/C housing. 4. Slide the two actuator mounting studs out of the slots in the actuator mounting bracket. 5. Pull the actuator downward far enough to access the clip that retains the actuator link to the recirculation air door lever. 6. Unsnap the clip from the actuator link and disengage the link from the recirculation air door lever. 7. Remove the actuator from the vehicle. INSTALLATION 1. Insert a screwdriver or another suitable tool through the recirculation air intake grille to prop the recirculation air door up in the open position far enough to access the recirculation air door lever through the access hole in the back of the glove box opening in the instrument panel. 2. Install the actuator link to the recirculation air door lever. 3. Snap the actuator link retainer clip onto the actuator link. 4. Remove the tool that is propping the recirculation door open. 5. Position the two actuator mounting studs into the slots in the actuator mounting bracket on the heater-A/C housing. 6. Tighten the two actuator mounting stud nuts to secure the actuator to the mounting bracket. 7. Connect the actuator vacuum line. 8. Install the glovebox in the instrument panel. Page 967 Neutral Safety Switch: Service and Repair 1. Raise and support vehicle, then place a suitable container beneath switch. 2. Unscrew switch from transmission case, allowing fluid to drain into container. 3. Move shift lever to Park and then to Neutral position and ensure switch operating lever is centered in switch opening in case. 4. Install a new seal on switch, then thread switch into transmission case. Torque to 25 ft-lbs then check and add transmission fluid as required. 5. Ensure switch operates properly. Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Page 601 Message Center Page 1003 Alignment: Service and Repair Front Alignment Preliminary Inspection 1. Ensure tires are of correct size and are inflated to recommended pressure. 2. Inspect front wheel bearings for wear and/or to verify proper adjustment. 3. Inspect ball studs, steering linkage pivot points and steering gear for excessive freeplay, roughness, binding or wear. 4. Inspect front wheels for excessive lateral or radial runout or imbalance. 5. Inspect suspension components for wear and improper tightening. Toe Adjustment With the front wheels in straight ahead position, loosen the clamps at each end of both adjusting tubes. Adjust toe-in by turning the tie rod sleeve which will "center" the steering wheel spokes. If the steering wheel was centered, make the toe-in adjustment by turning both sleeves an equal amount. Position sleeve clamps so ends do not align in the sleeve slot. Refer to "Front Wheel Alignment Specifications" for correct settings. Specifications Fuel Pressure: Specifications Fuel Pressure Note: Engine at curb idle. Fuel Pressure At Injectors ............................................................................................................................................................ 241 - 310 kPa (35 - 45 psi) Fuel Pump Output Pressure, Maximum ...................................................................................................................................................... 690 kPa (100 psi) Brake Pedal - Rattle While Driving Brake Pedal Assy: All Technical Service Bulletins Brake Pedal - Rattle While Driving NO: 05-08-96 GROUP: Brakes DATE: Sept. 13, 1996 SUBJECT: Brake Pedal Rattle MODELS: 1994 - 1996 (BR) Ram Truck SYMPTOM/CONDITION: Customers may complain of a rattle coming from the brake pedal area while driving. DIAGNOSIS: Drive the vehicle on a rough surfaced road. If a rattle is heard coming from the brake pedal area and is eliminated when pressure is applied to the side of the brake pedal, perform the following Repair Procedure. PARTS REQUIRED: 1 52009582 Wave Washer, Brake Pedal REPAIR PROCEDURE: This bulletin involves removing the brake pedal and installing a wave washer between the brake pedal and the brake pedal bushing. 1. Remove stop lamp fuse (fuse # 20) 2. Remove the knee bolster. 3. Remove stop lamp switch from mounting bracket, turning counter-clockwise. 4. Remove clip and washer attaching booster push rod and slide push rod off pedal. 5. Push shaft toward driver side of bracket just enough to expose left side E-clip then, remove E-clip with a flat blade screwdriver. 6. Push pedal shaft out of passenger side of bracket. 7. Remove brake pedal and pedal shaft from vehicle. Page 639 Power Door Locks (Part 2 Of 2) Page 1100 Normal Operation And Carbon Fouling 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 (.001 in) per 1600 km (1000 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 is not affected by MMT deposits. 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. 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 Page 1174 Air Injection Filter: Description and Operation Air Pump Air Filter The Air Injection Filter removes debris from the air before it enters the Air Injection Pump. This helps prolong pump life. The rubber tube at the inlet of the filter housing helps prevent air intake noise. Page 796 Manifold Pressure/Vacuum Sensor: Mechanical Specifications Mounting Bolt Torque .......................................................................................................................... .................................................... 2 Nm (20 in. lb.) Page 431 Front End Lighting With Daytime Running Lamps (Part 2 Of 2) Page 780 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Location REMOVAL 1. Disconnect negative battery cable. 2. Raise and support vehicle. 3. Disconnect sensor electrical connector. 4. Remove sensor mounting bolt. 5. Carefully remove sensor in a rocking motion with two small screwdrivers. 6. Remove sensor from vehicle. 7. Inspect sensor O-ring. Crankshaft Position Sensor Crankshaft Position Sensor Installation INSTALLATION 1. Apply a small amount of clean motor oil to sensor o-ring. 2. Install the sensor into the cylinder block with a slight rocking motion. Do not twist sensor into position as damage to sensor may result. Page 533 Intermittent Wiper System (Part 2 Of 2) Description and Operation Blower Motor Switch: Description and Operation Fig 3 Heater-Air Conditioner Control Panels The heater-only or heater-A/C blower motor is controlled by a rotary switch mounted in the heater-A/C control panel. The switch allows for the selection of four blower motor speeds and an Off position, but will only operate with the ignition switch in the On position, and the heater-A/C mode control switch in any position except Off. The blower motor switch is connected in series with the blower motor ground path through the heater-Air mode control switch. The blower motor switch directs this ground path to the blower motor through the blower motor resistor wires, or directly to the blower motor as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The switch is serviced only as a part of the heater-only or heater- A/C control assembly The blower motor switch knob is serviced separately. Page 565 Fuseblock (Part 1 Of 2) Page 497 Fuel Injection Ignition System (Part 6 Of 10) Page 459 Power Door Locks (Part 1 Of 2) Page 539 Stereo Radio System (Part 1 Of 2) Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The camshaft position sensor is mounted in the timing chain cover. Page 411 Air Bag Control Module Connector Air Bag Control Module Connector Related Images Locations ABS Light Relay: Locations Power Distribution Center Power Distribution Center Page 437 Multi-Function Switch Connector Page 74 Relay Box: Mechanical Diagrams Fig.12 Fuse Block And Relay Bank Page 641 Fuel Injection Ignition System (Part 2 Of 10) Page 85 Body Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 350 3. Remove the cup holder assembly from the instrument panel. 4. Remove the ash receiver from the ash receiver bracket. Fig. 2 5. Remove the two (2) screws that secure the ash receiver bracket to the instrument panel. 6. Remove the ash receiver bracket from the instrument panel. Fig. 3 7. Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers. 8. Unplug the wiring harness connector from the lighter. 9. Unplug the wiring harness connector from the auxiliary power outlet. 10. Set the cluster bezel aside. Fig. 4 11. Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel. 12. Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s). Page 841 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 619 Cargo And Dome Lamps Page 894 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Location REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting bolt. 4. Using two small screwdrivers, carefully pry sensor from timing chain cover. 5. Remove sensor from vehicle. 6. Inspect condition of o-ring. INSTALLATION (New Sensor) 1. Apply a small amount of clean motor oil to sensor o-ring. 2. Install the sensor into the timing cover with a slight rocking motion. Push the sensor all the way into the cover until the rib material on the sensor contacts the cam gear. 3. Install sensor mounting bolt and torque to 6 Nm (50 in-lbs). 4. Connect sensor electrical connector. Camshaft Position Sensor Installation Page 33 Blower Motor Relay: Testing and Inspection Blower Motor Relay Fig 39 Blower Motor Relay Removal/Installation RELAY TEST Remove the blower motor relay from its wire harness connector as described 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 75 +/- 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 the Relay Circuit Test procedure. If not OK, replace the 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 the open circuit to the fuse block module as required. 2. The relay normally closed terminal cavity (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 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. There should be continuity between this cavity and the blower motor relay output circuit cavity of the blower motor wire harness connector 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 electromagnet in the relay. It is energized when the ignition switch is in the On position. Check for 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 ignition switch through the Power Distribution Center (PDC) as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Page 691 Drive-Third Gear Fuel Gauge - Inaccurate Fuel Gauge Sender: Customer Interest Fuel Gauge - Inaccurate NO: 08-33-94 GROUP: Electrical DATE: Jul. 15, 1994 SUBJECT: Fuel Gauge Inaccuracy THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-58-93 DATED DEC. 10, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE BULLETIN REVISES THE FUEL PUMP MODULE INSTALLATION PROCEDURE AND THE VEHICLE BUILD RANGE. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - 1993 (AD) Ram Pick Up/Ramcharger 1991 - 1994 (AN) Dakota SYMPTOM/CONDITION: The fuel gauge may not read accurately. Customers may complain of too much reserve fuel in the tank when the gauge indicates empty or that they did not receive the larger capacity fuel tank they ordered. PARTS REQUIRED: 1991-1993 AN 1 4761780 (15 gallon) Sending Unit 4761651 (22 Gallon) Sending Unit 1 4773164 Harness **1994 Built before 01-03-94, MDH 01-03-XX)** 1 4773164 Harness 1991-1993 AD 1 4773164 Harness REPAIR PROCEDURE: This bulletin involves installing a wire harness that provides a common ground for the fuel gauge and the sending unit, and installing a revised sending unit on some models. For 1991 through 1993 Dakota Only. (All other models proceed to step 2). **NOTE: IT IS CRITICAL WHEN INSTALLING THE NEW FUEL PUMP/SENDING UNIT TO MARK THE POSITION OF THE ORIGINAL MODULE TO THE, FUEL TANK. WHEN INSTALLING THE NEW MODULE, ROTATE THE MODULE 1 INCH COUNTERCLOCKWISE FROM THE ORIGINAL POSITION.** 1. Using the procedures outlined in the appropriate Service Manual, replace the fuel gauge sending unit with the appropriate sending unit. FOR ALL MODELS: 2. Disconnect the battery. 3. Remove the connector from the fuel tank sending unit. 4. Remove the wedge lock from the connector being careful not break it. Page 662 Power Seat System Page 599 Vehicle Speed Control System (Part 1 Of 2) Page 701 Drive First Gear Page 130 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 477 ALPHABETICAL INDEX (Part 3 Of 6) Page 756 Camshaft Position Sensor: Testing and Inspection Sensor Connector 1. Disconnect the sensor pigtail harness from the main engine wiring harness connector. 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Page 623 Daytime Running Lamps Module Page 597 Anti-Lock Brake System (Part 3 Of 4) Component Locations Manifold Pressure/Vacuum Sensor: Component Locations MAP Sensor Location The Manifold Absolute Pressure (MAP) sensor is mounted on the intake manifold plenum. Page 447 84-way Connector Headlamp And Dash To Instrument Panel Wiring (Part 2 Of 2) Page 412 Vehicle will be equipped with one of these three connectors Page 197 Right Front Wheel Speed Sensor Connector Page 503 Horn System Page 577 Joint Connector(C) Page 71 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 526 Joint Connector(C) Wiring (Part 2 Of 2) Page 572 Engine Connector-A Page 965 Neutral Safety Switch Page 630 Overhead Map Lamp Page 693 Part Throttle 3-2 Kickdown Page 748 Engine Wiring Connector Locations Page 1096 Spark Plug: Testing and Inspection Cold Fouling/Carbon Fouling Normal Operation And 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 filter or repeated short operating times (short trips). Page 283 16. Tape the terminal back to the harness (See Figure 4). 17. Install the new harness terminal into cavity F. 18. Install the wedge. 19. Remove the IP ground nut (See Figure 5). 20. Install the harness ground eyelet and tighten the screw to 29 in.lbs. 21. Connect the cluster connectors, install the cluster and knee blocker. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. AN 08-45-30-99 1.9 Hrs. AD 08-45-30-99 0.7 Hrs. 08-45-30-60 (With Skid Plate) 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Page 777 Crankshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 98 Powertrain Control Module With Four Wheel Antilock Brakes Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes PURPOSE The Controller - Antilock Brake (CAB) is mounted under the hood, separately from the valve body, and has microprocessor circuits that: Monitor the brake switch input to tell whether or not to prepare for possible antilock braking. - Monitor the wheel speed sensor inputs to determine when a wheel is tending to lock up. - Operate the integral control unit assembly during antilock braking based on comparing the speed sensors to information programmed in memory. - Detect ABS system related problems and take diagnostic action. OPERATION The CAB will disable antilock control and set a soft ignition latched trouble code if it detects one of the following conditions with itself: (71) RAM Read/Write - (72) ROM Checksum - (73) Watchdog Page 517 Front End Lighting Without Daytime Running Lamps (Part 2 Of 2) Page 449 84-way Connector Instrument Panel To Headlamp And Dash Wiring (Part 2 Of 2) Specifications Idle Speed: Specifications Idle speed adjustment is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control motor (IAC), and is not adjustable. If idle is outside of specified RPM, or is rough, or unstable, inspect and clean throttle body if deposits are still visible. Page 534 Stop/Turn And Hazard Flasher System Page 457 Power Mirror System (Part 2 Of 2) Page 578 Rear Wheel Anti-Lock Control Module Connector Page 1093 Spark Plug: Description and Operation Spark Plug Cutaway View PURPOSE Spark plugs allow high-voltage secondary current to arc across a small air gap to ignite the air/fuel mixture in the combustion chamber. Spark Plug Temperature HEAT RANGE The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator, the smaller the heatsink area will be. This causes the spark plug to be hotter. The heat range of the plug is determined by its ability to dissipate heat created during combustion. If too cold a plug is used, the possibility of fouling is increased. A plug that is too hot can cause preignition. Hotter plugs tend to burn cleaner with less deposit build-up. They can be used for stop-start city driving, but not for extended high speed or load conditions as engine damage can occur. Page 39 Pinout Page 560 Rear Lighting (Part 2 Of 2) Page 70 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 580 Multi-Function Switch Connector Transmission Temperature Sensor - Fault Code Transmission Temperature Sensor/Switch: Technical Service Bulletins Transmission Temperature Sensor - Fault Code NO: 08-06-95 GROUP: Electrical DATE: Mar. 3, 1995 SUBJECT: Transmission Temperature Sensor - Fault Code MODELS: 1994 - 1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES WHICH ARE NOT EQUIPPED WITH A TRANSMISSION COOLER (SALES CODE - NHB). DISCUSSION: If the ORB gives a fault code "Trans. Temp. Sensor Failed" and the vehicle is not equipped with a transmission cooler, the fault code should be cleared and ignored. A software miscommunication may cause this fault to be set in vehicles without a transmission temperature sensor (No Sales Code - NHB). If the vehicle is equipped with a Transmission Cooler (Sales Code - NHB), it will have a transmission temperature sensor and the appropriate Diagnostic Manual should be followed. Do not attempt to install a transmission temperature sensor on vehicles not equipped with the auxiliary transmission cooler. POLICY: Information Only Component Locations Neutral Safety Switch: Component Locations Neutral Safety Switch The Park/Neutral Switch is mounted on the transmission. Page 84 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 927 Page 734 Fig.11 Engine Compartment Wiring (Part 3 Of 4) Locations Air Bag Control Module And Control Module Connector Page 496 Fuel Injection Ignition System (Part 5 Of 10) Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 767 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications 1. Disconnect the wire harness connector from the coolant temperature sensor. 2. Test the resistance of the sensor with a digital volt-ohmmeter. The measured resistance should be less than 1340 ohms with the engine warm. Refer to the above sensor resistance chart for exact values. 3. Replace sensor if it is not within the range of resistance specified in the chart. 4. Test the resistance of the wire harness. Check between the Powertrain Control Module (PCM) terminal 2 and the appropriate sensor connector terminal. Also check between PCM 4 and the appropriate sensor terminal. Repair the wire harness if the resistance is greater than 1 ohm or if an open circuit is indicated. 5. After tests are completed, re-connect electrical connector to sensor. Connector is symmetrical (not indexed); it can be installed to the sensor in either direction. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 859 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 504 Airbag System (Part 1 Of 2) Page 311 6. Connect the single wire connector from the overlay harness to the ground terminal on the headlamp switch assembly. Fig. 4 7. Tuck the relay pack into the instrument panel pocket on the left side between the demister duct and the HVAC duct and then install the headlamp switch into the instrument panel. Tighten the three attaching screws securely. 8. Connect the lighter wiring connector. 9. Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel. Fig. 3 10. Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel. Fig. 2 11. Install the ash receiver bracket. Tighten the bracket screws securely. 12. Install the ash receiver. Page 254 High Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH Verify that the refrigerant system has the correct refrigerant charge. 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Page 984 Transmission Temperature Sensor/Switch: Mechanical Specifications Torque ................................................................................................................................................. ........................................................ 11 Nm (8 ft. lb.) Page 34 Blower Motor Relay: Service and Repair Fig 39 Blower Motor Relay Removal/Installation NOTE: The blower motor relay and wire harness connector are snap-fit onto a blade-type retainer located on the stop lamp switch mounting bracket. The stop lamp switch mounting bracket is secured with two screws to the inboard side of the brake pedal support bracket, under the driver side of the instrument panel. To remove the relay: 1. Disconnect and isolate the battery negative cable. 2. Reach under the knee blocker on the driver side of the instrument panel between the throttle and brake pedals, and unsnap the relay from the blade on the stop lamp switch bracket. 3. Lower the relay from under the instrument panel far enough to unplug the relay from the wire harness connector. 4. To install the relay, align the terminals with the cavities in the relay wire harness connector and push the relay firmly into place. 5. Reverse the remaining removal procedures to complete the installation. 6. Test the relay operation. Page 482 Fuse Application Chart (Part 2 Of 3) Page 791 Intake Air Temperature Sensor: Testing and Inspection Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications 1. Disconnect the wire harness connector from the intake manifold temperature sensor. 2. Test the resistance of the sensor with a digital volt-ohmmeter. The measured resistance should be less than 1340 ohms with the engine warm. Refer to the above sensor resistance chart for exact values. 3. Replace sensor if it is not within the range of resistance specified in the chart. 4. Test the resistance of the wire harness. Check between the Powertrain Control Module (PCM) terminal 21 and the appropriate sensor connector terminal. Also check between PCM 4 and the appropriate sensor terminal. Repair the wire harness if the resistance is greater than 1 ohm. Page 722 Fig.10 Engine Splices Page 986 Transmission Temperature Sensor/Switch: Description and Operation DESCRIPTION The transmission temperature sensor is a variable, thermistor type. It reacts to temperature changes. At cold transmission oil temperatures, its resistance is high. As temperatures increase, its resistance will decrease. The transmission temperature sensor is used on models equipped with an automatic transmission and a factory installed transmission cooler. It is also used on models equipped with certain heavy-duty options and an automatic transmission (8.0L V-10 / 5.9L turbo diesel with 47RH transmission). Transmission Temperature Sensor LOCATION The transmission temperature sensor is located in the transmission cooler outlet line, next to the transmission. Transmission Temperature Warning Lamp An instrument panel-mounted transmission temperature warning lamp is also used. PURPOSE Its purpose is to help control transmission fluid overheating. NOTE: Fourth gear and converter clutch operation in the 47RH are normally controlled by the PCM, but are also controlled by the temperature sensor under certain conditions. OPERATION The temperature sensor constantly monitors transmission fluid temperature. The sensor is in circuit with overdrive and converter clutch solenoid through the Powertrain Control Module (PCM). The temperature sensor prevents overdrive and converter clutch engagement when fluid temperature is below 60 °F for the overdrive clutch; and below 70 °F for the converter clutch. If the fluid temperature indicator lamp comes on, fluid temperature is either at, or above 285°F. This indicates an approaching overheat condition. The sensor will downshift the transmission to third gear and possibly disengage the converter clutch. At this point, it will be necessary to Page 506 Rear Wheel ABS System (Part 1 Of 2) Page 514 Clearance And Identification Lamps Page 417 Left Door Connector (Part 1 Of 2) Page 260 Low Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH Verify that the refrigerant system has the correct refrigerant charge. 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Page 730 Fig.7 Instrument Panel Wiring (Part 2 Of 2) Page 932 Specifications Compression Check: Specifications Cylinder Compression Pressure .......................................................................................................... ................................................................ 170-190 psi Maximum Allowable Variance Between Cylinders ........................................................................................................................................................ 25% Page 181 181 Oxygen Sensor - Rough Idle/Lack of Power/Black Smoke Oxygen Sensor: Customer Interest Oxygen Sensor - Rough Idle/Lack of Power/Black Smoke NO: 18-06-95 GROUP: Vehicle Performance DATE: Feb. 3, 1995 SUBJECT: Engine Runs Poorly, Lacks Power Idles Rough And/Or Blows Black Smoke MODELS: 1994-1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L H.D. OR 8.0L ENGINES BUILT PRIOR TO SEPTEMBER 1, 1994 (MDH 09-01-XX) SYMPTOM/CONDITION: Engine runs poorly, lacks power, idles rough and/or may blow black smoke at operating temperatures. DIAGNOSIS: Test drive vehicle, ensuring that vehicle is at full operating temperatures. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII 1994 MY or, DRBIII 1995 MY) with appropriate diagnostic procedure manual, check the 02 circuits for the sensor outputs. If any of the above symptoms are present or DRB II/III (Scan Tool) diagnosis indicates left 02 sensor output stuck on rich rail and right on lean rail, proceed with the repair procedure. REPAIR PROCEDURE: This bulletin involves correction of the two 02 sensors at the wire harness connectors. 02 Sensor Harness 02 Sensor Harness 1. With the vehicle on a hoist examine the left (Figure 1) and right (Figure 2) O2 sensor wires at the black connectors. Both sensor's wire harness connections should have a BK/LB wire, DG/O wire and BK/W wire. 2. The remaining wire in the right O2 sensor connector should be a black/dark green wire. The remaining wire in the Left O2 sensor connector should be a tan/white wire. 3. If the wires in step 2 are reversed, disconnect the two O2 sensor connectors and reconnect them in the opposite sensors. For routing refer to Page 628 Headlamp Switch And Joint Connector(A) Wiring (Part 2 Of 2) Page 179 177 Page 764 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Torque ................................................................................................................................................. ........................................................ 11 Nm (8 ft. lb.) Page 436 Cigar Lighter And Glove Box Lamp Page 11 Related Images Page 218 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 766 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The sensor element extends into the coolant passage where it maintains constant contact with the engine coolant. The Powertrain Control Module (PCM) uses this sensor to measure the temperature of engine coolant. OPERATION The PCM sends out a reference voltage of approximately five (5) volts to the engine coolant temperature sensor. As coolant temperature changes, the internal resistance of the sensor will change, causing a varying voltage drop across the sensor. The PCM reads the voltage drop across the sensor as engine coolant temperature. Based on the amount of voltage drop at the coolant sensor, the PCM will, adjust the fuel injector pulse width (a cold engine will receive a longer pulse width, allowing for a richer mixture), compensate for condensation of fuel in the intake manifold, monitor and adjust engine warm-up speed, and advance ignition timing when the engine is cold. Page 462 Data Link Connector Page 786 Intake Air Temperature Sensor: Mechanical Specifications Torque ................................................................................................................................................. ...................................................... 28 Nm (20 ft. lb.) Page 177 71 Page 876 Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation PURPOSE This sensor is used to send input signals to the Powertrain Control Module (PCM) to indicate the current angle of the throttle blade. THEORY/OPERATION This sensor is a variable resistor that has a 5 volt reference signal applied to it by the PCM. The Throttle Position Sensor (TPS) sends signals back to the PCM in the range of approximately 1 to 4 volts, depending upon the throttle shaft angle. The PCM uses these input voltages to determine the current position of the throttle. The PCM uses the voltage signals from the TPS and other input sensors to determine the proper air/fuel mixture and ignition timing for certain operating conditions. Some of these operating conditions are: acceleration, deceleration, idle, and wide open throttle. TYPICAL READINGS An input voltage of approximately 1 volt indicates a minimum throttle opening, idle, or deceleration condition. An input voltage of approximately 2 volts indicates a cruise or light acceleration condition. An input voltage of approximately 4 volts would indicate a maximum throttle opening or wide open throttle condition. Page 944 7. Lift the battery tray up far enough to access the speed control servo wire harness connector. 8. Unplug the wire harness connector from the speed control servo. 9. Move the battery tray far enough to access the impact sensor. 10. Remove the three screws that secure the impact sensor to the front wheelhouse extension. 11. Unplug the wire harness connector from the impact sensor and remove the sensor. Page 726 Fig.3 Cab Wiring Recall - Headlamp Switch Technical Service Bulletin # 819 Date: 990601 Recall - Headlamp Switch June 1999 Dealer Service Instructions for: Safety Recall No. 819 - Headlamp Switch MODELS 1994-1997 (BR) Dodge Ram 3500 Series Trucks NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. SUBJECT Extended operation of the lights on about 79,000 of the above vehicles can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. REPAIR The headlamp switch must be replaced and a parklamp circuit relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced. PARTS INFORMATION Part Number Description CAJM8190 Headlamp Switch Package Each package contains the following components: Quantity Description 1 Headlamp Switch 1 Overlay Relay Harness 1 2-Way Female Connector 1 2-Way Wedge 1 Headlamp Switch Connector 1 Headlamp Switch Connector Wedge 1 Wire Kit (Contains 9 individual wires with terminals at one end) 9 Heat Shrink Tubing Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Headlamp Switch Packages to service about 25% of those vehicles. SERVICE PROCEDURE A. Remove the Headlamp Switch Assembly: 1. Disconnect the negative battery cable(s). Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. Fig. 1 2. Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel. Engine Compartment - Flutter Noise on Deceleration Air Injection Pump: All Technical Service Bulletins Engine Compartment - Flutter Noise on Deceleration NO: 18-27-95 GROUP: Vehicle Performance DATE: Aug. 18, 1995 SUBJECT: Flutter Noise From Engine Compartment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-28-94, DATED DEC. 23, 1994, WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (81-699-95054). THE AIR FILTER HOUSING NO LONGER CONTAINS A GREEN MARK. THE CHANGE IS MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Flutter noise emitted from the engine compartment on closed throttle decelerations/light acceleration between 1500 to 1800 RPM. DIAGNOSIS: Test drive vehicle steadily accelerating. Take foot off throttle and listen for flutter or popping noise. If noise is found, perform repair procedure. PARTS REQUIRED: 1 4324506 Air Pump - Air Filter Housing REPAIR PROCEDURE: This bulletin involves the replacement of the existing air pump. ** The air filter housing is no longer marked with a green mark on the main part label, all parts are the updated version.** 1. Remove the silencer tube at the housing. 2. Remove the air inlet tube at the housing. 3. Remove the rubber cap. 4. Remove the mounting bracket strap bolt. 5. Note the position of the tube fittings before removing filter housing assembly from bracket. Gently bend the strap and remove filter housing assembly. 6. Install the air filter housing assembly to the mounting bracket. 7. Install and tighten strap bolt. 8. Install air inlet tube, silencer tube and cap at filter housing. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 25-01-08-90 0.2 Hrs. FAILURE CODE: P8 - New Part Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 183 191 Page 1077 Figure 3 Figure 4 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-22-92 .....0.4 Hrs. FAILURE CODE: C2 - Panel Interference Page 513 Vehicle Speed Control System (Part 2 Of 2) Page 680 Fig. 40 Serpentine Drive Belt Routing Fig. 40 Serpentine Drive Belt Routing Page 723 SPLICE INDEX HARNESS INDEX Page 987 determine the cause of the overheat condition (e.g. cooler restricted, blocked, vehicle overloaded, not equipped for towing, etc.). If transmission overheating has been determined by this sensor (fluid temperature exceeds 27O 275 °F), an input is sent to the PCM. The PCM will then force a 4-3 downshift, or will prevent a 3-4 upshift. Once transmission temperature has cooled below specifications, a 3-4 upshift will be allowed. Page 657 Infinity Stereo Radio System (Part 2 Of 2) Page 681 Fig. 42 Serpentine Drive Belt Routing Page 512 Vehicle Speed Control System (Part 1 Of 2) Page 174 63 Page 542 Infinity Stereo Radio System (Part 2 Of 2) Page 239 Oil Pressure Sender: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 699 Neutral Page 544 Heater System Page 720 Fig.7 Engine Compartment Splices (Part 1 Of 2) Page 828 Oxygen Sensor: Application and ID Page 733 Fig.10 Engine Compartment Wiring (Part 2 Of 4) Page 665 Fuse Application Chart (Part 1 Of 3) Page 523 Headlamp Switch And Joint Connector(A) Wiring (Part 2 Of 2) Page 863 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) Typical PURPOSE The Vehicle Speed Sensor (VSS) is used to inform Powertrain Control Module (PCM) of vehicle deceleration and engine idle. The PCM uses this information to control Idle Air Control (IAC) motor position during these conditions. PCM uses sensor input with input from Throttle Position Sensor (TPS) and VSS to differentiate between closed throttle deceleration or closed throttle idle. During closed throttle deceleration, (slower signals received from sensor), PCM actuates the IAC motor to maintain desired Manifold Absolute Pressure (MAP) sensor value. During idle, (no signals being received from sensor), the PCM actuates the IAC motor to maintain desired engine idle speed. The vehicle speed sensor input signal is also used as a mileage reference for the Service Reminder Indicator (SRI) lamp. OPERATION The VSS has a set of contacts inside that are opened and closed by a rotating 8 pole permanent magnet. As the magnet rotates, the magnetic field opens and closes the contacts 8 times per revolution, or 8000 times per mile. The PCM sends a 8 volt signal to the VSS. If the sensors contacts are open, the voltage stays at 8 volts. If the contacts are closed, the voltage will drop to 0 volts. Page 443 Multi-Function Switch Connector Page 219 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 640 Fuel Injection Ignition System (Part 1 Of 10) Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 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 temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. 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. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. 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. Accidental airbag deployment could occur. Page 27 Electronic Brake Control Module: Service and Repair With Rear Wheel Antilock System 1. Remove knee bolster; then, using a suitable long-shank screwdriver, remove electronic control module lower mounting screws. 2. Remove module upper mounting screw, then lower module and bracket assembly from underside of instrument panel. 3. Disconnect electrical harness from module; then, if necessary, separate module from bracket so that a new module may be installed. 4. Reverse procedure to install. Page 729 Fig.6 Instrument Panel Wiring (Part 1 Of 2) Page 719 Fig.6 Instrument Panel Splices (Part 2 Of 2) Page 82 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 1085 Ignition Cable: Service and Repair Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or ignition coil, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Firing Order V10 When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs, or 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. Page 936 POLICY: Information Only Page 516 Front End Lighting Without Daytime Running Lamps (Part 1 Of 2) Component Locations Oxygen Sensor: Component Locations Page 928 ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Page 554 Automatic Day/Night Mirror Page 537 Cluster Connector-B Printed Circuit Board Page 470 Trailer Tow System And Ground Joint (Part 2 Of 2) Page 1108 Compression Check: Service Precautions COMPRESSION TESTING When performing a compression test, remove the fuel pump relay fuse and disconnect power to the ignition. This will stop fuel flow to the injectors and prevent engine from starting. Locations Fuel Pump Relay: Locations Power Distribution Center Power Distribution Center The fuel pump relay is located inside the power distribution center, at the left rear corner of the engine compartment. Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor Location The camshaft position sensor is mounted in the timing chain cover. Page 653 Radio And Sensor Ground Page 735 Fig.12 Engine Compartment Wiring (Part 4 Of 4) Page 340 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 ADDITIONAL INFORMATION If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter SAFETY RECALL TO REPLACE YOUR TRUCK'S HEADLAMP SWITCH AND INSTALL A RELAY WIRING HARNESS Dear Dodge Ram 3500 Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1994 through 1997 Dodge Ram 3500 Series trucks. The problem is... Driving your Ram truck (identified on the enclosed form) with the lights on for an extended time frame can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. What DaimlerChrysler and your dealer will do... Daimlerchrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the headlamp switch and do install a relay wiring harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your saftey... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call l-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Page 888 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 413 Overhead Console Connector Page 108 Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Terminals The relay terminal numbers can be found on the bottom of the relay. - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Page 530 Overhead Console (Part 1 Of 2) Page 702 Drive Second Gear Page 625 Cigar Lighter And Glove Box Lamp Page 684 Fig.12 Fuse Block And Relay Bank Page 175 67 Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test NOTES: ^ A four gas analyzer will be needed to perform this test. ^ This test should be performed only after sensor functional test, and sensor heating element tests are passed. ^ When performing this test it is important that no part of your body contact the vehicle body, as inaccurate test results may result. CAUTION: NEVER apply voltage directly to any computer sensor wire. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 RPM for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 2. With engine OFF, disconnect oxygen sensor connector and connect a jumper lead to the computers oxygen sensor return wire, terminal 2 of the electrical connector. 3. Start engine and run at 2500 rpm for 1 minute with the transmission in PARK (A/T) or NEUTRAL (M/T). 4. Let engine idle. 5. Simulate a rich command (lean condition), by touching one hand to jumper wire and other hand to battery negative, for 10 to 20 seconds. HC and O2 readings should begin to increase. 6. Simulate a lean command (rich condition), by touching one hand to jumper wire and other hand to battery positive, for 10 to 20 seconds. HC and O2 readings should begin to decrease, and CO should begin to increase. 7. If computer system fails to respond to these artificial commands, further testing of the oxygen sensor circuit and/or computerized engine control system will be necessary. Page 524 Joint Connector(B) Wiring Page 621 Clearance And Identification Lamps Heat/Defrost Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Heat/Defrost Door Actuator Replacement Fig 49 Heat-Defrost Door Actuator HEAT-DEFROST DOOR ACTUATOR Removal 1. Remove the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 2. Turn the heater-A/C housing upside down. 3. Disconnect the vacuum line from the heat-defrost door actuator. 4. Separate the heat-defrost door crank arm from the door pivot pin. 5. Remove the crews that secure the actuator to the heater-A/C housing. 6. Remove the heat-defrost door actuator. Installation 1. Install the heat-defrost door actuator to the heater-A/C housing. 2. Install and tighten the Screws that secure the actuator to the heater-A/C housing. 3. Press the heat-defrost door crank arm onto the door pivot pin. 4. Connect the vacuum line to the heat-defrost door actuator. 5. Install the heater-A/C housing. Page 666 Fuse Application Chart (Part 2 Of 3) Page 356 6. Connect the single wire connector from the overlay harness to the ground terminal on the headlamp switch assembly. Fig. 4 7. Tuck the relay pack into the instrument panel pocket on the left side between the demister duct and the HVAC duct and then install the headlamp switch into the instrument panel. Tighten the three attaching screws securely. 8. Connect the lighter wiring connector. 9. Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel. Fig. 3 10. Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel. Fig. 2 11. Install the ash receiver bracket. Tighten the bracket screws securely. 12. Install the ash receiver. Diagrams Page 499 Fuel Injection Ignition System (Part 8 Of 10) Page 582 Left Door Connector (Part 1 Of 2) Testing and Inspection Brake Fluid: Testing and Inspection NOTE: Swollen rubber parts indicate the presence of petroleum in the brake fluid. To confirm that contamination exists, make the following test: Place a small amount of the drained brake fluid into a small clear glass bottle. Separation of the fluid into distinct layers will indicate mineral oil content. If there is any question of mineral oil content, drain system, flush thoroughly and replace all rubber parts. Page 1188 NOTE: Make sure that the paint mark at the thermostat end of the hose lines up with the bolt on the thermostat housing for proper orientation (Figure 2). 4. Install plastic manifold cap by snapping it over the A/C compressor manifold (Figure 3). 5. Close drain plug and fill system using saved fluid. Top off system with 50/50 mixture of water and antifreeze. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-30-30-90 0.3 Hrs. FAILURE CODE: PS - New Part Page 451 Headlamp Switch And Joint Connector(A) Wiring (Part 1 Of 2) Diagrams Power Mirror Switch Connector Page 548 Power Window System -- Part 2 Page 536 Cluster Connector-A Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Page 182 187 Page 446 84-way Connector Headlamp And Dash To Instrument Panel Wiring (Part 1 Of 2) Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Page 144 Air Bag Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 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 temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. 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. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. 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. Accidental airbag deployment could occur. Stop Light Switch - Wiring Connector Service Stop Lamp Switch: Technical Service Bulletins Stop Light Switch - Wiring Connector Service NO.: 08-67-93 GROUP: Electrical DATE: Dec. 31, 1993 SUBJECT: Stop Light Switch Wiring Connector Service MODELS: 1995 (PL) Neon 1994 (AA) Spirit/Acclaim/LeBaron Sedan 1994 (AJ) LeBaron Convertible 1994 (AP) Shadow/Sundance 1994 (AS) Caravan/Voyager/Town & Country 1994 (BR) Ram Pickup 1994 (LH) Concorde/Intrepid/Vision 1994 (LH) LHS/New Yorker 1994 (ZJ) Grand Cherokee SYMPTOM/CONDITION: When servicing the stop light switch or wiring connector, the stop light switch wiring connector may be difficult to remove from stop light switch. Attempts to remove the wiring connector may damage the insulator wedge or the switch itself. REPAIR PROCEDURE: This bulletin involves removing the stop light switch with wiring connector attached as an assembly before disconnecting the wiring connector. 1. Remove the stop light switch, with wiring connector still attached to the switch, by turning the switch counterclockwise 1/16 turn and pulling straight out of the mounting bracket. 2. Depress and hold down both locking tabs on the "blue" wiring insulator wedge and pull the wiring connector from the stop light switch insulator, Figure 1. NOTE: DISCONNECTING THE WIRING CONNECTOR HARNESS FROM THE SWITCH BY PULLING ON THE WIRING MAY RESULT IN OPEN CIRCUITS. Page 355 3. Install the switch knob and shaft on the new switch assembly by depressing the release button on the bottom of the switch assembly and then inserting the shaft into the switch assembly. Fig. 10 4. Connect the 9-way wiring connector to the headlamp switch. Fig. 10 5. Connect the 2-way wiring connector to the headlamp switch (if equipped). Fig. 10 Page 815 Figures 1 & 2. 4. Verify that the wires are connected properly as listed in step 2. 5. All fault codes should be cleared using the ORB II/III (Scan Tool). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 25-01-70-97 0.5 Hrs. Sensor, Oxygen - Reroute Wires and Reconnect. 94-95 BR FAILURE CODE: WV - Wiring Misrouted Air Pump Belt Adjustment Drive Belt: Adjustments Air Pump Belt Adjustment This engine is equipped with an automatic belt tensioner and adjustment is not required. Page 484 Power Distribution Center Page 481 Fuse Application Chart (Part 1 Of 3) Page 834 Oxygen Sensor: Service and Repair WARNING: Exhaust manifold becomes very hot during engine operation. CAUTION: The oxygen sensor has a permanently attached wire and connector. This should not be removed or pulled on, as any change in circuit resistance will affect engine performance and emissions. CAUTION: Excessive force may damage threads in exhaust manifold or pipe. 1. Disconnect oxygen sensor electrical connector. 2. Using a suitable tool (tool # C-4907 or equivalent), carefully remove the sensor from exhaust manifold or pipe. The oxygen sensor may be easier to remove when engine temperature is above 120°F. 3. Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. 4. If a new sensor is being used, verify that the threads are coated with anti-seize compound, before installing in manifold or pipe. NOTE: Do not use graphite based anti-seize compounds. 5. If a used sensor is being installed, coat sensor threads with a nickel based anti-seize compound (Loctite 771-64 or equivalent), then install sensor in manifold or pipe. 6. Torque sensor to 30 Nm (22 ft-lbs), connect wiring. Page 966 Neutral Safety Switch: Description and Operation PURPOSE Signals the Powertrain Control Module (PCM) of gear selection. OPERATION On vehicles equipped with automatic transmissions, the park/neutral switch indicates if the transmission is in NEUTRAL, PARK, or a DRIVE GEAR. Based on input from this switch the PCM will adjust fuel injector pulse width, ignition timing advance, and idle speed. Page 629 Horn System ABS Control Module Electronic Brake Control Module: Locations ABS Control Module The Rear Wheel Anti-Lock (RWAL) control module is located behind the instrument panel, to the right of the steering column, and near the intermittent wiper module. Page 603 Overhead Console (Part 2 Of 2) Page 590 Airbag System (Part 2 Of 2) Page 398 Vehicle: Diagrams Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 617 Cigar Lighter And Glove Box Lamp Page 1136 Front Axle Lubricant AR 4467707 Mopar High Performance Synthetic Axle Lube (amount specified by transfer case.) REPAIR PROCEDURES: This bulletin involves replacing the lubricant in the front axle, and in some cases, replacing the above listed parts in the transfer case. FRONT AXLE LUBRICANT REPLACEMENT: 1. Using a suction pump, remove as much axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube as specified below. BR Truck - 4F Axle Fill to within 1/4" of the bottom of the fill plug hole (approximately 77 ounces). BR Truck - 6OF Axle Fill to within 1/2" of the bottom of the fill plug hole (approximately 122 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. TRANSFER CASE COMPONENT REPLACEMENT: 1. After completing the above front axle lubricant change, test the shifting effort. 2. If high shifting effort or inconsistent shifting is occurring, replace the synchronizer assembly referencing Group 21 in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-03-01-93 (Fluid, Front Axle-Replace, 1994-1995) 0.3 Hrs. Page 846 Throttle Position Sensor: Testing and Inspection TPS / IAC Motor Location The throttle position sensor (TPS) can be tested with a digital voltmeter. The sensor must be checked on the vehicle with its three wire connector engaged to the sensor. The center terminal wire of the sensor connector is the output terminal. 1. Remove the air filter housing assembly. 2. Carefully attach a paper clip into the center terminal of the sensor harness. 3. Attach the positive (+) lead of the voltmeter to this paper clip. 4. Attach the negative (-) lead of the voltmeter to a good ground. With the ignition key in the ON position and engine not running, check the sensor output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, sensor output voltage should be greater than 200 millivolts. At wide open throttle, sensor output voltage must be less than 4.8 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Page 424 Joint Connector(B) Page 838 Throttle Position Sensor: Locations TPS / IAC Motor Location The throttle position sensor is mounted on throttle body. A/C - Air Door Actuator Service Procedures Revision Air Door Actuator / Motor: Technical Service Bulletins A/C - Air Door Actuator Service Procedures Revision NUMBER: 26-01-97E GROUP: Miscellaneous DATE: January, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1994 Ram Truck - Publication Number 81-370-4108 DESCRIPTION OF CHANGES Revision to the recirculating air door actuator procedures. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 282 5. Remove the terminal from cavity # 2 (See Figure 1). 6. Insert the terminal from the harness, P/N 4773164, into cavity # 2. 7. Install the wedge into the connector. 8. Install the connector to the sending unit. 9. Tie strap the harness along the chassis to the original harness following it into the engine compartment. 10. Drill a 1/2" hole in the dash panel as shown in Figure 2. 11. Route the harness through the hole and seat the grommet. 12. Remove the knee blocker, the IP cluster and disconnect the cluster connectors. 13. Route the harness through the dash to the cluster area. 14. Remove the wedge from the cluster connector (See Figure 3) being careful not to break it. 15. Remove the terminal from cavity F (AN Body) or A (AD Body). (See Figure 3). Page 54 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 851 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Page 1137 21-03-01-94 (Synchronizer, Replace, 1994-1995) 2.1 Hrs. Optional Equipment 21-03-01-60 (Skid Plate Equipped, 1994-1995) 0.4 Hrs. FAILURE CODE: P8 - New Part Page 645 Fuel Injection Ignition System (Part 6 Of 10) Page 685 Power Distribution Center Page 438 Center High Mounted Stop Lamp Page 465 Stereo Radio System (Part 2 Of 2) Page 173 59 Page 704 Drive Fourth Gear (Converter Clutch Not Applied) Entertainment Device - Front Door Speaker Buzz Speaker: All Technical Service Bulletins Entertainment Device - Front Door Speaker Buzz NUMBER: 08-16-00 GROUP: Body DATE: April 28, 2000 SUBJECT: Front Door Speaker Buzz OVERVIEW: This bulletin involves installing a urethane foam pad between the inner door panel and the door trim. MODELS: 1994 - 2000 (BR/BE) Ram Truck SYMPTOM/CONDITION: Buzz noise coming from the front door speaker(s). The noise may be more noticeable while listening to "talk" radio segments with deep male voices. DIAGNOSIS: Tune the radio to "talk" radio program preferably with male voices. Adjust the equalizer to achieve maximum bass tones, if equipped. If noise can be isolated to the front door speakers, or the owner describes noise in the front door speaker, perform the Repair Procedure. PARTS REQUIRED: 2 05018968M Kit, Foam AR (26) 06505878AA Clips, Door Trim Attaching REPAIR PROCEDURE: This repair is compatible with Daimler/Chrysler's mobile service program and does not require hoists or other full service facility special equipment. 1. Roll the window(s) down. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with a diesel engine, disconnect and isolate both battery negative cables. 3. On vehicles equipped with a manual window regulator, remove the window crank (Figure 1). 4. Remove the screw that attaches the trim panel to the outside mirror frame (Figure 2). 5. Remove the screws that attach the pull cup to the door. 6. Using a trim panel removal tool such as Snap On tool A161B, disengage the trim panel retaining clips from the door. Base models, have eleven trim panel retaining clips (clips 12 and 13 not used) and premium models have thirteen (Figure 3). It is very important that a trim panel tool is used to separate each retaining clip from the door. CAUTION: Damage to the door trim panel may occur if the door trim panel retaining clips are separated from the door without using a trim panel removing tool. door panels should never be removed by hand. 7. While holding the bottom of the trim panel away from the door, simultaneously lift upward and inboard to detach the trim panel from the door. 8. Peel the protective backing from the foam (from Foam Kit p/n 05018968AA) and place the foam onto the inner door panel trim as shown in Figure 4. 9. Remove all door trim panel retaining clips 10. Install new door trim panel retaining clips p/n 06505878AA onto the door trim panel. 11. Position the trim panel onto the door. 12. Engage all door trim panel attaching clips around the perimeter of the trim panel, attaching trim panel to the inner door. 13. Install the screws securing the pull cup to the inner door panel. Page 441 Daytime Running Lamps Module Page 7 Warning Lamp Relay Fuel Gauge - Sticks at Full Intermittently Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Sticks at Full Intermittently NO: 08-10-94 GROUP: Electrical DATE: Feb. 18, 1994 SUBJECT: Fuel Gauge Sticks MODELS: 1994 (BR) Ram Truck SYMPTOM/CONDITION: The fuel gauge may intermittently stick at full with less than a full tank of fuel. PARTS REQUIRED: 1 52127747 Pump Module (26 and 35 gal. 3.9L, 5.2L, 5.9L) 1 52127748 Pump Module (35 gal 5.9L HD, sales code EMM) 1 52127749 Pump Module (35 gal. 5.9L Diesel, sales code ETB) REPAIR PROCEDURE: This bulletin involves replacing the fuel pump module. Using the procedures outlined in the 1994 Ram Truck Service Manual, Publication Number 81-370-4108, page 14-4, replace the fuel pump module with the appropriate part listed in the Parts Required section. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.14-50-02-90.......1.3 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Page 492 Fuel Injection Ignition System (Part 1 Of 10) Recall - Headlamp Switch Technical Service Bulletin # 819 Date: 990601 Recall - Headlamp Switch June 1999 Dealer Service Instructions for: Safety Recall No. 819 - Headlamp Switch MODELS 1994-1997 (BR) Dodge Ram 3500 Series Trucks NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. SUBJECT Extended operation of the lights on about 79,000 of the above vehicles can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. REPAIR The headlamp switch must be replaced and a parklamp circuit relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced. PARTS INFORMATION Part Number Description CAJM8190 Headlamp Switch Package Each package contains the following components: Quantity Description 1 Headlamp Switch 1 Overlay Relay Harness 1 2-Way Female Connector 1 2-Way Wedge 1 Headlamp Switch Connector 1 Headlamp Switch Connector Wedge 1 Wire Kit (Contains 9 individual wires with terminals at one end) 9 Heat Shrink Tubing Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Headlamp Switch Packages to service about 25% of those vehicles. SERVICE PROCEDURE A. Remove the Headlamp Switch Assembly: 1. Disconnect the negative battery cable(s). Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. Fig. 1 2. Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel. Page 57 Daytime Running Lamp Control Unit: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 339 Fig. 1 13. Install the cup holder assembly. Tighten the cup holder screws securely. 14. Connect the negative battery cable(s). COMPLETION REPORTING AND REIMBURSEMENT Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerClrrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace headlamp switch and 08819182 0.5 hours install overlay harness Replace headlamp switch, install 08819183 0.9 hours overlay harness and replace 4 wires Replace headlamp switch, install 08819184 1.1 hours overlay harness and replace 5-9 wires Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions PARTS RETURN Not required. DEALER NOTIFICATION AND VEHICLE LIST All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL SYSTEM FUNCTIONS 53 AND VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD819". OWNER NOTIFICATION AND SERVICE SCHEDULING All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. VEHICLE NOT AVAIABLE If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Page 890 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 445 Multi-Function Switch Connector Page 91 PCM Location Page 864 Vehicle Speed Sensor: Testing and Inspection Testing of the Vehicle Speed Sensor should only be done with the DRB or an equivalent scan-tool. Refer to Computers and Control Systems/Testing and Inspection/Procedures. Page 675 Transmission Overdrive System (Part 3 Of 3) Page 775 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 638 Power Door Locks (Part 1 Of 2) Page 520 Daytime Running Lamps Module Page 648 Fuel Injection Ignition System (Part 9 Of 10) Page 170 51 Page 781 NOTE: Before tightening sensor mounting bolt, be sure sensor is flush to cylinder block. 3. Install sensor mounting bolt and torque to 8 Nm (70 in-lbs). 4. Connect sensor electrical connector. 5. Lower vehicle. Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Locations ABS Light Relay: Locations Power Distribution Center Power Distribution Center Page 483 Fuse Application Chart (Part 3 Of 3) Page 677 Power Window System -- Part 2 Page 918 8D - 38A Oxygen Sensor - Rough Idle/Lack of Power/Black Smoke Oxygen Sensor: All Technical Service Bulletins Oxygen Sensor - Rough Idle/Lack of Power/Black Smoke NO: 18-06-95 GROUP: Vehicle Performance DATE: Feb. 3, 1995 SUBJECT: Engine Runs Poorly, Lacks Power Idles Rough And/Or Blows Black Smoke MODELS: 1994-1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L H.D. OR 8.0L ENGINES BUILT PRIOR TO SEPTEMBER 1, 1994 (MDH 09-01-XX) SYMPTOM/CONDITION: Engine runs poorly, lacks power, idles rough and/or may blow black smoke at operating temperatures. DIAGNOSIS: Test drive vehicle, ensuring that vehicle is at full operating temperatures. Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII 1994 MY or, DRBIII 1995 MY) with appropriate diagnostic procedure manual, check the 02 circuits for the sensor outputs. If any of the above symptoms are present or DRB II/III (Scan Tool) diagnosis indicates left 02 sensor output stuck on rich rail and right on lean rail, proceed with the repair procedure. REPAIR PROCEDURE: This bulletin involves correction of the two 02 sensors at the wire harness connectors. 02 Sensor Harness 02 Sensor Harness 1. With the vehicle on a hoist examine the left (Figure 1) and right (Figure 2) O2 sensor wires at the black connectors. Both sensor's wire harness connections should have a BK/LB wire, DG/O wire and BK/W wire. 2. The remaining wire in the right O2 sensor connector should be a black/dark green wire. The remaining wire in the Left O2 sensor connector should be a tan/white wire. 3. If the wires in step 2 are reversed, disconnect the two O2 sensor connectors and reconnect them in the opposite sensors. For routing refer to Page 1082 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Page 306 13. Pull the headlamp switch control knob out to the ON position stop. 14. Depress the switch knob and shaft release button on the bottom of the switch assembly and then pull the switch knob and shaft out of the switch. Fig. 5 15. Remove the three screws that secure the headlamp switch bezel to the switch mounting bracket and then remove the bezel. Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket from the switch assembly. Discard the switch assembly. B. Install the Parklamp Circuit Overlap Harness: 1. Remove the wedge from the 9-way headlamp switch wiring connector. Fig. 6 2. Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage. Page 697 Reverse Page 169 47 Page 209 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Component Locations Ignition Control Module: Component Locations ICM Location The Ignition Control Module (ICM) is mounted on the right fender apron, behind the coolant recovery bottle. Page 615 Rear Lighting (Part 1 Of 2) Page 656 Infinity Stereo Radio System (Part 1 Of 2) Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the two battery holddown bolts. 3. If equipped, pull up on the battery heat shield to remove it. 4. Remove the battery from the vehicle. Specifications 1994 - 1999 8.0L (488) Page 549 Power Door Locks (Part 1 Of 2) Page 1012 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test Before performing this test, verify fuel pump pressure by performing the previous tests. 1. Release the fuel system pressure from fuel system. Refer to Fuel Pressure Release Procedure. 2. Disconnect the fuel supply line at fuel rail. The fuel line-to-fuel rail connection is made at the rear of the engine. Remove air cleaner housing before tool connection. 3. Connect Fuel Line Pressure Test Adapter Tool number 6631 (3/8 in.), or number 6539 (5/16 in.) into the disconnected fuel supply line (tube). Insert the other end of Adapter Tool 6631 or 6539 into an approved gasoline container. 4. Use the DRB scan tool to activate the fuel pump and pressurize the system. 5. A good fuel pump will deliver approximately 2 liters of fuel per minute. Page 113 Fuel Pump Relay: Description and Operation PURPOSE The relay supplies battery voltage to fuel pump and oxygen sensor heater element when energized by Powertrain Control Module (PCM). OPERATION The PCM energizes fuel pump relay by supplying relay ground, when ignition switch is in START or RUN position and PCM is receiving a reference signal from distributor. When the PCM does not receive reference signal from ignition system, (indicating engine is not running), then the PCM interrupts relay ground circuit and no voltage is supplied to fuel pump, ignition coil, or oxygen sensor heater element. The PCM controls fuel pump relay and Auto Shutdown (ASD) relay simultaneously, through same ground circuit. Recall - Headlamp Switch Technical Service Bulletin # 819 Date: 990601 Recall - Headlamp Switch June 1999 Dealer Service Instructions for: Safety Recall No. 819 - Headlamp Switch MODELS 1994-1997 (BR) Dodge Ram 3500 Series Trucks NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. SUBJECT Extended operation of the lights on about 79,000 of the above vehicles can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. REPAIR The headlamp switch must be replaced and a parklamp circuit relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced. PARTS INFORMATION Part Number Description CAJM8190 Headlamp Switch Package Each package contains the following components: Quantity Description 1 Headlamp Switch 1 Overlay Relay Harness 1 2-Way Female Connector 1 2-Way Wedge 1 Headlamp Switch Connector 1 Headlamp Switch Connector Wedge 1 Wire Kit (Contains 9 individual wires with terminals at one end) 9 Heat Shrink Tubing Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Headlamp Switch Packages to service about 25% of those vehicles. SERVICE PROCEDURE A. Remove the Headlamp Switch Assembly: 1. Disconnect the negative battery cable(s). Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. Fig. 1 2. Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel. Page 191 Wheel Speed Sensor: Specifications Wheel Speed Sensors 1000 - 2500 ohms Page 47 Warning Lamp Relay Page 738 Fig.15 Transmission Wiring (Manual) Page 604 Heater System Component Locations Stop Lamp Switch: Component Locations Brake Switch The brake switch is mounted on the brake pedal support bracket. Page 435 Rear Lighting (Part 2 Of 2) Page 420 Right Door Connector (Part 2 Of 2) Front Valve Body (HCU) Connector Page 115 Fuel Pump Relay: Service and Repair Power Distribution Center REMOVAL 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 1. Install relay to PDC. 2. Install cover to PDC. Page 1193 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - With disc brakes, fluid level can be expected to fall as the brake pads wear. - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". 1. Wipe caps and reservoir clean to prevent dirt and foreign matter from dropping into the reservoir. 2. Remove the caps to check the level. - On aluminum master cylinder add DOT 3 fluid to bring the level to the bottom of the primary split ring. - On the cast iron master cylinder, add DOT 3 fluid to bring the level to within a 1/4 inch of the top of reservoir. CAUTION: Use fluid other than DOT 3 that may have a lower boiling point -- such as fluid identified as 7OR1 or unidentified as to specification -- could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Page 272 16. Tape the terminal back to the harness (See Figure 4). 17. Install the new harness terminal into cavity F. 18. Install the wedge. 19. Remove the IP ground nut (See Figure 5). 20. Install the harness ground eyelet and tighten the screw to 29 in.lbs. 21. Connect the cluster connectors, install the cluster and knee blocker. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. AN 08-45-30-99 1.9 Hrs. AD 08-45-30-99 0.7 Hrs. 08-45-30-60 (With Skid Plate) 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94E GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Ram Truck - Publication No. 81-370-4108 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Page 1148 21-03-01-94 (Synchronizer, Replace, 1994-1995) 2.1 Hrs. Optional Equipment 21-03-01-60 (Skid Plate Equipped, 1994-1995) 0.4 Hrs. FAILURE CODE: P8 - New Part Page 167 43 Page 463 Powertrain Control Module Page 171 55 Page 230 Speed Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Page 647 Fuel Injection Ignition System (Part 8 Of 10) Page 414 Anti-Lock Brake System Controller Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Page 705 Drive Fourth Gear (Converter Clutch Applied) Page 860 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 646 Fuel Injection Ignition System (Part 7 Of 10) Page 1011 Fuel Pressure Test - Typical Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from Gauge Set 5069) to test port pressure fitting on fuel rail. 2. With engine running, note pressure gauge reading. Fuel pressure should be approximately 241-310 kPa (35-45 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and check to see if the relay is actuating properly. Refer to Computers and Control Systems/Testing and Inspection/Procedures. 4. If operating pressure is above 45 psi, fuel pump is OK. Replace fuel filter/fuel pressure regulator assembly. Page 401 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Page 211 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Sensor Location The engine coolant temperature sensor threads into intake manifold, next to the thermostat housing. Page 672 Trailer Tow System And Ground Joint (Part 2 Of 2) Page 407 Engine Connector-A Testing and Inspection Speed Control Switch: Testing and Inspection 1. Disconnect the blade type four wire electrical connector from base of steering column. 2. Using a continuity tester, or an ohmmeter, check for continuity at connector wires. Do not use a test light. Fig. 108 Speed Control Continuity Chart Fig. 8 Speed Control Connector Terminal Identification 3. Results should be obtained according to the charts. If these results are not obtained, replace switch. Page 1083 Ignition Cable: Description and Operation PURPOSE The spark plug wires connect the terminals in the coil pack to the spark plugs, allowing high voltage to flow to the spark plugs. CONSTRUCTION The ignition wires have an internal resistance to suppress radio static and to eliminate static that may interfere with sensitive computer components. Page 551 Power Mirror System (Part 1 Of 2) Page 571 84-way Connector Headlamp And Dash To Instrument Panel Wiring (Part 2 Of 2) Page 728 Fig.5 Door Wiring Page 474 Multi-Function Switch Connector Page 989 Transmission Temperature Sensor/Switch: Service and Repair Removal 1. Raise and support vehicle 2. Place drain pan below the sensor 3. Clean area around sensor before removal 4. Disconnect the electrical connector at sensor 5. Remove (unthread) the sensor from transmission cooling line. to prevent twisting and damage to cooler line, be sure to use a back up wrench on cooling line. installation 1. Install the sensor into the transmission cooling line. tighten sensor to 11 Nm (8ft lbs) torque. 2. Connect the electrical connector at sensor 3. Lower vehicle 4. Check and adjust automatic transmission fluid. Page 40 Compressor Clutch Relay: Description and Operation Compressor Clutch Relay 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 on the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches 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 heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. 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. Page 1153 Drive Belt: Adjustments Drive Belt Tension Adjustment 1. A new beltrun for 15 minutes is considered a used belt. 2. On models with 3.9L/V6-238 & 5.2L/V8-318 engines equipped with automatic belt tensioner, no adjustment is provided. 3. All engines equipped with automatic belt tensioner, no adjustment is provided. Page 985 Transmission Temperature Sensor/Switch: Locations Transmission Temperature Sensor Location The transmission temperature sensor is located in the transmission cooler outlet line, next to the transmission. Page 248 Blower Motor Switch: Testing and Inspection The blower motor switch is only serviced as a part of the heater-only or heater-A/C control assembly. 1. Turn the ignition switch to the Off position. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the control wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the 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 control as you move the blower switch 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 control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Power Distribution Center The Auto Shutdown (ASD) relay is located inside the power distribution center (PDC). The power distribution center is located at the left-hand rear corner of the engine compartment. Refer to PDC cover for exact placement of the relay within the PDC assembly. Page 695 Manual Second Gear (2) Page 416 Related Images Page 532 Intermittent Wiper System (Part 1 Of 2) Page 502 Engine Oil Pressure And Engine Coolant Temp. System Ignition - Tamper Resistant Ignition Cylinder Addition Ignition Switch Lock Cylinder: Technical Service Bulletins Ignition - Tamper Resistant Ignition Cylinder Addition NUMBER: 23-44-94E GROUP: Body DATE: Jun. 3, 1994 Models: 1994 Ram Truck - Publication No. 81-370-4108 DISCUSSION: A new method of ignition key cylinder retention is used on the subject vehicles for improved vehicle security. The ignition key cylinder retaining pin has been replaced with a tamper resistant screw and a bracket, refer to the illustration. A Snap-On TTXR20A2 torx-bit or equivalent is required to remove the screw. The 1995 Dakota service manual was completed prior to this information being available to Service Publications. The vehicles listed as 1994 models only, will have this information already in their corresponding 1995 service manual. DESCRIPTION OF CHANGES Add Tamper Resistant Ignition Key Cylinder Info. Page 891 Camshaft Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Left Left Front Wheel Speed Sensor Connector Page 988 Transmission Temperature Sensor/Switch: Testing and Inspection To perform a complete test of this sensor and its circuitry, refer to DRB scan tool and appropriate test procedures. To test the sensor only, refer to the following: Transmission Temperature Sensor 1. Disconnect the wire harness connector from the temperature sensor. The sensor is located on the side of the transmission in the transmission cooling line. Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be less than 1340 ohms with the engine warm. Refer to the Transmission Temperature Sensor resistance chart. Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (PCM) wire harness connector terminal 42 and the sensor connector terminal. Also check between terminal 4 to the sensor connector terminal. Repair the wire harness as necessary if the resistance is greater than 1 ohm. Page 510 Anti-Lock Brake System (Part 3 Of 4) Page 370 Transfer Case Actuator: Description and Operation The disconnect axle control system consists of; Vacuum control switch on the transfer case, air vent filter, shift motor, indicator switch, vacuum switch , two check valves, and a harness. Page 535 Message Center Page 1198 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Page 305 3. Remove the cup holder assembly from the instrument panel. 4. Remove the ash receiver from the ash receiver bracket. Fig. 2 5. Remove the two (2) screws that secure the ash receiver bracket to the instrument panel. 6. Remove the ash receiver bracket from the instrument panel. Fig. 3 7. Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers. 8. Unplug the wiring harness connector from the lighter. 9. Unplug the wiring harness connector from the auxiliary power outlet. 10. Set the cluster bezel aside. Fig. 4 11. Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel. 12. Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s). Page 752 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 103 - The Powertrain Control Module (PCM) prepositions the idle air control (IAC) motor. - The PCM reads atmospheric air pressure from the manifold absolute pressure (MAP) sensor and calculates the basic fuel strategy. - The PCM monitors the throttle position sensor (TPS) and engine coolant temperature (ECT) sensor input. The PCM uses these inputs to modify fuel strategy. - Intake air temperature (IAT) sensor is monitored. - The Automatic Shutdown (ASD) relay is energized for 3 seconds. - Fuel pump is energized for 1 second, unless engine is running or cranking. - Oxygen sensor heating element is energized. - Up shift indicator light is illuminated (M/T only). Limp-In Mode NOTE: If the Malfunction Indicator Lamp (MIL), is illuminated during vehicle operation, the vehicle has entered limp-in. PURPOSE Allows reduced vehicle operation, if one or more inputs fail. (The vehicle should be driven to a service facility as soon as possible.) OPERATION In Limp-in mode the Powertrain Control Module (PCM) substitutes the input of an alternate sensor, for that of the failed sensor, and continues to monitor the faulty sensor input. If the faulty sensor input returns within limits, and remains within limits long enough, the PCM will resume normal operation. Wide Open Throttle Mode This is an OPEN LOOP mode. During wide open throttle operation the Powertrain Control Module (PCM) receives the following inputs: - Battery voltage - Camshaft position (CMP) sensor - Engine coolant temperature (ECT) sensor Manifold absolute pressure (MAP) sensor - Intake air temperature (IAT) sensor - Crankshaft position (CKP) sensor - Throttle position sensor (TPS) Based on these inputs the PCM will: - Apply voltage to the injectors. The PCM then controls injection sequence and pulse width by switching individual injector ground paths on and off. Oxygen sensor input is ignored. The PCM will supply a predetermined amount of additional fuel. - Monitor oxygen sensor and fine tune air/fuel ratio by varying injector pulse width. - Adjust ignition timing. - De-energize A/C Compressor Clutch relay (if selected). Page 668 Power Distribution Center Page 147 Air Bag Control Module: Service and Repair WARNING: ^ The airbag control module contains one of the impact sensors, which enable the system to deploy the airbag. Never strike or kick the air bag control module. 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 air bag system. Failure to do this could result in accidental airbag deployment and possible personal injury. ^ The airbag control module must never be relocated from its factory-installed position. The plastic airbag control module protective cover must always be reinstalled following any service removal. Care should be exercised to protect the airbag control module from direct spray or submersion in water or other liquids. Never strike the airbag control module with tools or other objects. Never stand on or place objects on the airbag control module. Failure to heed these warnings could result in accidental airbag deployment, or non-deployment of the airbag when needed, and possible personal injury. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the two screws that secure the airbag control module trim cover to the mounting bracket on the floor pan transmission tunnel under the instrument panel. 3. Using a wide flat-bladed tool such as a trim stick, gently pry the top of the trim cover away from the mounting bracket to release the snap clip retainer that secures it to the mounting bracket. NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. 4. Remove the four screws that secure the airbag control module mounting bracket to the floor pan transmission tunnel. 5. Slide the airbag control module out from under the instrument panel far enough to unplug the wire harness connectors from the module. 6. Remove the airbag control module and mounting bracket as a unit. 7. When installing the airbag control module and mounting bracket, position the unit with the arrow on the module housing pointing forward. 8. Plug in the wire harness connectors to the air-bag control module. Be certain that the connector latches are fully engaged. 9. Attach the airbag control module to the floor pan transmission tunnel with the four mounting screws. Tighten the mounting screws to 11.8 to 16.3 N.m (105 to 145 in. lbs.). 10. Install the airbag control module trim cover. 11. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. Locations Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Power Distribution Center The Auto Shutdown (ASD) relay is located inside the power distribution center (PDC). The power distribution center is located at the left-hand rear corner of the engine compartment. Refer to PDC cover for exact placement of the relay within the PDC assembly. General Operation Powertrain Control Module: Description and Operation General Operation As input signals to the Powertrain Control Module (PCM) change, The PCM adjusts its response that it sends to the output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). Likewise the PCM changes ignition timing to compensate for different operating conditions. There are nine modes of operation that determine how the PCM responds to the various input signals. Modes of operation are separated into two different types. - OPEN LOOP - CLOSED LOOP During Open Loop modes the PCM receives input signals and responds only to preset PCM programming. Input from the oxygen (02) sensor is not monitored during Open Loop modes. During Closed Loop modes the PCM monitors the oxygen sensor input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts of air to 1 part of fuel. By monitoring the exhaust oxygen content, using the oxygen sensor, the PCM can "fine tune" the injector pulse width to achieve optimum fuel economy and performance combined with low emission levels. The sequential multi-point fuel injection (SFI) 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, deceleration, acceleration, wide open throttle, and ignition switch OFF modes are Open Loop modes. The Cruise and Idle modes, with the engine at operating temperature, are Closed Loop modes. Page 564 Headlamp Switch Connector Page 255 High Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch on the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Page 194 Wheel Speed Sensor: Connector Locations Left Front Wheel Speed Sensor Connector Right Front Wheel Speed Sensor Connector Page 1150 Fig. 42 Serpentine Drive Belt Routing Page 553 Power Seat System Page 508 Anti-Lock Brake System (Part 1 Of 4) Page 642 Fuel Injection Ignition System (Part 3 Of 10) Page 690 Drive-Second Gear Page 421 Front Valve Body (HCU) Connector Rear Valve Body (RWAL) Connector Page 198 Wheel Speed Sensor: Description and Operation NOTE: The EBH-5H ABS system uses one wheel speed sensor on each front wheel, and one speed sensor mounted in the rear axle for the rear wheels. CONSTRUCTION Each sensor has: Metal tone wheel with teeth on its outside diameter - Magnet/coil pick-up (speed sensor) that is mounted to the knuckle - Air gap between the tone wheel and the speed sensor assembly OPERATION The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel pair is transmitted to the Controller - Antilock Brake (CAB). As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the antilock module takes control. Diagnostically, the coil of each wheel speed sensor will have approximately 1000 to 2500 ohms of resistance. Each front wheel speed is monitored through the speed sensor mounted at the front hub. The rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, complete the antilock warning light circuit, and store trouble codes if it detects a problem with any or all of the wheel speed sensors: Incorrect circuit resistance when checked with no vehicle movement - Incorrect sensor output during vehicle movement - Erratic sensor output during vehicle movement Page 940 Impact Sensor: Description and Operation DESCRIPTION Two impact sensors and a safing sensor provide verification of the direction and severity of an impact. The safing sensor is located inside the Airbag Control Module (ACM), which is mounted to a bracket on the floor transmission tunnel, under the instrument panel. The two impact sensors are mounted on the inner fender extension panels behind the grille opening reinforcement, on the left and right sides of the vehicle. OPERATION The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The safing sensor is an accelerometer that senses the rate of deceleration. The sensors are calibrated for the specific vehicle, and are sensitive to both the severity and the direction of an impact. The microprocessor in the ACM monitors the sensor signals. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the driver side airbag. REPLACEMENT The impact sensors and safing sensor cannot be repaired or adjusted and, if faulty or damaged, they must be replaced. The impact sensors are available for service replacement. The safing sensor is only serviced as part of the ACM. CIRCUIT OPERATION Two airbag impact sensors provide input to the Air-bag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 1 of the 13-way connector. Circuit R49 connects to one cavity of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 13 of the 13-way connector. Circuit R48 connects to cavity 12 of the 13-way connector. Specifications Crankshaft Position Sensor: Specifications Torque ................................................................................................................................................. ....................................................... 8 Nm (70 in. lb.) Page 540 Stereo Radio System (Part 2 Of 2) Page 201 Wheel Speed Sensor: Service and Repair Rear With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor Page 69 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Fuel Gauge - Inaccurate Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Inaccurate NO: 08-33-94 GROUP: Electrical DATE: Jul. 15, 1994 SUBJECT: Fuel Gauge Inaccuracy THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-58-93 DATED DEC. 10, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE BULLETIN REVISES THE FUEL PUMP MODULE INSTALLATION PROCEDURE AND THE VEHICLE BUILD RANGE. THE CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1991 - 1993 (AD) Ram Pick Up/Ramcharger 1991 - 1994 (AN) Dakota SYMPTOM/CONDITION: The fuel gauge may not read accurately. Customers may complain of too much reserve fuel in the tank when the gauge indicates empty or that they did not receive the larger capacity fuel tank they ordered. PARTS REQUIRED: 1991-1993 AN 1 4761780 (15 gallon) Sending Unit 4761651 (22 Gallon) Sending Unit 1 4773164 Harness **1994 Built before 01-03-94, MDH 01-03-XX)** 1 4773164 Harness 1991-1993 AD 1 4773164 Harness REPAIR PROCEDURE: This bulletin involves installing a wire harness that provides a common ground for the fuel gauge and the sending unit, and installing a revised sending unit on some models. For 1991 through 1993 Dakota Only. (All other models proceed to step 2). **NOTE: IT IS CRITICAL WHEN INSTALLING THE NEW FUEL PUMP/SENDING UNIT TO MARK THE POSITION OF THE ORIGINAL MODULE TO THE, FUEL TANK. WHEN INSTALLING THE NEW MODULE, ROTATE THE MODULE 1 INCH COUNTERCLOCKWISE FROM THE ORIGINAL POSITION.** 1. Using the procedures outlined in the appropriate Service Manual, replace the fuel gauge sending unit with the appropriate sending unit. FOR ALL MODELS: 2. Disconnect the battery. 3. Remove the connector from the fuel tank sending unit. 4. Remove the wedge lock from the connector being careful not break it. Specifications Camshaft Position Sensor: Specifications Torque ................................................................................................................................................. ........................................................ 6 Nm (50 in. lb) Page 973 Overdrive Switch: Testing and Inspection The electrical controls governing the shift into fourth gear consist of the control switch on the instrument panel and the overdrive solenoid on the valve body. The control switch is in circuit with the solenoid and must be in the ON position to energize the solenoid. The transmission must also have reached third gear range before the shift to fourth gear will occur. The control 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. Page 755 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The signal from the camshaft position sensor combined with the input signal from the Crankshaft Position (CKP) Sensor, are what the Powertrain Control Module (PCM) uses to differentiate between fuel and spark events. Input is also used to properly synchronize fuel injection. OPERATION The PCM identifies cylinders by monitoring signals from the crankshaft and camshaft position sensors. The PCM uses these input signals to determine fuel injector synchronization. The Ignition Control Module (ICM) uses these input signals to determine which ignition coil to fire. The camshaft position sensor generates a high/low voltage signal, as slots in the camshaft gear are detected. When a slot passes in front of the sensor, a 5 volt signal is sent to the PCM. When a slot is not present, the PCM receives a 0.3 volt signal. If PCM does not sense input from cam position sensor, PCM will deactivate the automatic shutdown relay and fuel pump relay, interrupting voltage to fuel pump, fuel injectors, and ignition coil, causing a no start condition. Page 415 Rear Wheel Anti-Lock Control Module Connector Related Images Page 925 Page 107 Automatic Shut Down (ASD) Relay: Description and Operation PURPOSE The Automatic Shutdown (ASD) Relay supplies battery voltage to fuel pump relay, fuel injectors, ignition coil, and O2 sensor heating element, when energized by Powertrain Control Module (PCM). OPERATION The PCM energizes the ASD relay by supplying relay ground, when ignition switch is in START or RUN position and PCM is receiving a reference signal from the camshaft and crankshaft position sensors. When the ground is applied, the relay is energized, and voltage is allowed to flow to fuel pump, fuel injectors, ignition coil, generator field winding, and O2 sensor heating element. When PCM does not receive reference signal from ignition system, (indicating engine is not running), then the PCM interrupts relay ground circuit and no voltage is supplied to fuel pump, fuel injectors, ignition coil, generator field winding, and O2 sensor heating element. The PCM controls fuel pump relay and ASD relays simultaneously, through same ground circuit. Page 567 Powertrain Control Module Page 467 Infinity Stereo Radio System (Part 2 Of 2) Page 714 Fig.1 Frame Wiring Splices Page 488 Engine Starter System Page 904 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 664 Engine Starter System Charging System For infomation regarding diagrams for this system, please refer to Starting and Charging diagrams. See: Starting and Charging/Diagrams Page 885 Engine Wiring Connector Locations Locations Starter Relay: Locations Power Distribution Center Power Distribution Center Page 538 Fuel Tank System Page 485 Charging System Page 1066 Figure 3 Figure 4 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-22-92 .....0.4 Hrs. FAILURE CODE: C2 - Panel Interference Page 740 Fig.20 Four Wheel Drive Wiring Page 618 Stop/Turn And Hazard Flasher System Page 97 Powertrain Control Module: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 543 Radio And Sensor Ground Page 180 179 Page 213 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications 1. Disconnect the wire harness connector from the coolant temperature sensor. 2. Test the resistance of the sensor with a digital volt-ohmmeter. The measured resistance should be less than 1340 ohms with the engine warm. Refer to the above sensor resistance chart for exact values. 3. Replace sensor if it is not within the range of resistance specified in the chart. 4. Test the resistance of the wire harness. Check between the Powertrain Control Module (PCM) terminal 2 and the appropriate sensor connector terminal. Also check between PCM 4 and the appropriate sensor terminal. Repair the wire harness if the resistance is greater than 1 ohm or if an open circuit is indicated. 5. After tests are completed, re-connect electrical connector to sensor. Connector is symmetrical (not indexed); it can be installed to the sensor in either direction. Page 683 Fuseblock (Part 2 Of 2) Page 486 Ignition Switch (Part 1 Of 2) Page 261 Low Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch on the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Page 210 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Torque ................................................................................................................................................. ........................................................ 11 Nm (8 ft. lb.) Page 141 Air Bag Control Module Connector Page 353 Fig. 8 5. Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R". Retape the wiring bundle as necessary. Fig. 8 6. For vehicles WITHOUT headlamp switch connector or terminal heat damage: Remove the PINK w/RED TRACER wire from location "B2" and the BLACK w/YELLOW TRACER wire from location "R" of the headlamp switch connector using a small screwdriver, Miller Special Tool # 8197 or equivalent. Fig. 9 7. Insert the wire terminals that were originally in locations "B2" and "R" of the headlamp wiring connector into the supplied 2-way wiring connector. Insert the PINK wired TRACER wire into the (+) cavity. Insert the BLACK w/YELLOW TRACER wire into the (-) cavity. Secure the terminals with the provided 2-way wedge. Page 790 Intake Air Temperature Sensor: Description and Operation PURPOSE The Intake Manifold Air Temperature sensor element extends into the incoming airstream to measure the temperature of the air passing through the intake manifold. OPERATION The Powertrain Control Module (PCM) sends out a reference voltage of approximately five (5) volts to the charge air temperature sensor. As air temperature changes, the internal resistance of the sensor will change, causing a varying voltage drop across the sensor. The PCM reads the voltage drop across the sensor as charge air temperature. The PCM uses this information to calculate the proper injector pulse width and spark advance. Page 433 Front End Lighting Without Daytime Running Lamps (Part 2 Of 2) Page 476 ALPHABETICAL INDEX (Part 2 Of 6) Page 602 Overhead Console (Part 1 Of 2) Page 1120 8. Install the bolt and torque it to 312 Nm (230 ft. lbs.). NOTE: USE A BAR TO LOCK THE PULLEY IN PLACE WHILE TIGHTENING. 9. Install a new accessory drive belt following service manual procedures. 10. Reinstall the radiator following service manual procedures. 11. Reinstall the negative battery cable. 12. Fill the cooling system with the saved coolant and operate the vehicle to purge air from the system. Top off the automatic transmission fluid (if required). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 09-25-25-90 1.5 Hrs. FAILURE CODE: P8 - New Part Page 902 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 892 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor PURPOSE The signal from the camshaft position sensor combined with the input signal from the Crankshaft Position (CKP) Sensor, are what the Powertrain Control Module (PCM) uses to differentiate between fuel and spark events. Input is also used to properly synchronize fuel injection. OPERATION The PCM identifies cylinders by monitoring signals from the crankshaft and camshaft position sensors. The PCM uses these input signals to determine fuel injector synchronization. The Ignition Control Module (ICM) uses these input signals to determine which ignition coil to fire. The camshaft position sensor generates a high/low voltage signal, as slots in the camshaft gear are detected. When a slot passes in front of the sensor, a 5 volt signal is sent to the PCM. When a slot is not present, the PCM receives a 0.3 volt signal. If PCM does not sense input from cam position sensor, PCM will deactivate the automatic shutdown relay and fuel pump relay, interrupting voltage to fuel pump, fuel injectors, and ignition coil, causing a no start condition. Page 634 Automatic Day/Night Mirror Page 423 Cluster Connector-B Joint Connector(A) Page 706 Manual Low (1) Description and Operation Overdrive Switch: Description and Operation PURPOSE Signals the Powertrain Control Module (PCM) of overdrive selection. OPERATION On vehicles equipped with overdrive, the PCM controls 3-4 overdrive up-shift and down-shift through the overdrive solenoid. The overdrive/override switch is normally closed. When the switch is depressed the transmission will not enter overdrive, however if already in overdrive transmission will downshift to third gear. The overdrive switch circuit also contains a thermo-switch and coolant temperature switch. If either switch opens transmission will not shift into overdrive. Page 569 84-way Connector Instrument Panel To Headlamp And Dash Wiring (Part 2 Of 2) Page 1147 Front Axle Lubricant AR 4467707 Mopar High Performance Synthetic Axle Lube (amount specified by transfer case.) REPAIR PROCEDURES: This bulletin involves replacing the lubricant in the front axle, and in some cases, replacing the above listed parts in the transfer case. FRONT AXLE LUBRICANT REPLACEMENT: 1. Using a suction pump, remove as much axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube as specified below. BR Truck - 4F Axle Fill to within 1/4" of the bottom of the fill plug hole (approximately 77 ounces). BR Truck - 6OF Axle Fill to within 1/2" of the bottom of the fill plug hole (approximately 122 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. TRANSFER CASE COMPONENT REPLACEMENT: 1. After completing the above front axle lubricant change, test the shifting effort. 2. If high shifting effort or inconsistent shifting is occurring, replace the synchronizer assembly referencing Group 21 in the appropriate Service Manual. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-03-01-93 (Fluid, Front Axle-Replace, 1994-1995) 0.3 Hrs. Page 826 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 96 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 614 Front End Lighting Without Daytime Running Lamps (Part 2 Of 2) Page 188 207 Ignition Cable - Engine Miss and/or Rough Idle Ignition Cable: Customer Interest Ignition Cable - Engine Miss and/or Rough Idle NO: 18-09-95 Rev. A GROUP: Vehicle Performance DATE: Apr. 21, 1995 SUBJECT: Engine Miss and/or Rough Idle THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-09-95 DATED MAR. 10, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. MODELS: 1994-1995 (BR) Ram Pickup NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L V10 ENGINE BUILT PRIOR TO 2/14/94 (MDH 02-14-XX). SYMPTOM/CONDITION: Engine miss and/or rough idle may be experienced. The cause of the engine miss and/or rough idle may be the secondary ignition cables shorting at the coil boot. DIAGNOSIS: This condition will normally show NO fault codes. It may mislead the technician into diagnosing this problem as being related to a base engine component malfunction, such as stuck lifters or valve train problems. It the vehicle is brought in for service with vehicle performance complaints (rough idle, engine miss), and the ORB scantool does not show any fault codes, check ignition cables for the date code of 1st quarter 1994 (1-94) or earlier. The date code will appear as follows: NOTE: DATE CODING IS DONE QUARTERLY ON WIRES. EXAMPLE IS GIVEN BELOW. MOPAR ELECTRONIC SUPPRESSION GX 1-94 AATH GX = Material Code 1-94 = Date Code - Represents the 1st Quarter of 1994 AATH = Vendor Identification **NOTE: IF THE IGNITION CABLES ARE FOUND TO BE DATED THE FIRST QUARTER OF 1994 (1/94) OR EARLIER, THEY SHOULD BE REPLACED WITH CABLES DATED 2ND QUARTER (2/94) AND LATER**. POLICY: information Only Page 600 Vehicle Speed Control System (Part 2 Of 2) Page 129 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 930 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Page 1101 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.) 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. 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 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition 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. Page 547 Power Window System -- Part 1 Page 724 Fig.1 Rear Lamp Wiring Page 934 PARTS REQUIRED: Page 561 Trailer Tow System And Ground Joint (Part 1 Of 2) Windshield Wiper Switch Wiper Switch: Service and Repair Windshield Wiper Switch Refer to "Multi-Function Switch, Replace" in this section. Page 357 Fig. 1 13. Install the cup holder assembly. Tighten the cup holder screws securely. 14. Connect the negative battery cable(s). COMPLETION REPORTING AND REIMBURSEMENT Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerClrrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace headlamp switch and 08819182 0.5 hours install overlay harness Replace headlamp switch, install 08819183 0.9 hours overlay harness and replace 4 wires Replace headlamp switch, install 08819184 1.1 hours overlay harness and replace 5-9 wires Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions PARTS RETURN Not required. DEALER NOTIFICATION AND VEHICLE LIST All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL SYSTEM FUNCTIONS 53 AND VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD819". OWNER NOTIFICATION AND SERVICE SCHEDULING All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. VEHICLE NOT AVAIABLE If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Page 59 Daytime Running Lamps Module Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Test Port Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Page 842 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 439 Clearance And Identification Lamps Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications Temperature VS. Voltage Curve NOTE: For information on how this type of sensor operates SEE, Powertrain Management/Computers and Control Systems/Coolant Temperature Sensor/Description and Operation. NOTE: Measure resistance using a high impedance Digital Volt Ohmmeter (DVOM). COLD CURVE (Reference voltage routed to sensor through PCM internal resistance of 10k ohm) Temperature ........................................................................................................................................ ........................................ Voltage -20° F ................................................................................................................................................... ....................................... 4.70 V -10° F ................................................................................................................................................... ....................................... 4.57 V 0° F ...................................................................................................................................................... ...................................... 4.45 V 10° F .................................................................................................................................................... ....................................... 4.30 V 20° F .................................................................................................................................................... ....................................... 4.10 V 30° F .................................................................................................................................................... ....................................... 3.90 V 40° F .................................................................................................................................................... ....................................... 3.60 V 50° F .................................................................................................................................................... ....................................... 3.30 V 60° F .................................................................................................................................................... ....................................... 3.00 V 70° F .................................................................................................................................................... ....................................... 2.75 V 80° F .................................................................................................................................................... ....................................... 2.44 V 90° F .................................................................................................................................................... ....................................... 2.15 V 100° F .................................................................................................................................................. ........................................ 1.83 V 110° F .................................................................................................................................................. ........................................ 1.57 V Component Locations Intake Air Temperature Sensor: Component Locations Intake Manifold Air Temperature Sensor The intake manifold air temperature sensor is threaded into the left side of the intake manifold near the front of the throttle body. Page 570 84-way Connector Headlamp And Dash To Instrument Panel Wiring (Part 1 Of 2) Page 908 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Location REMOVAL 1. Disconnect negative battery cable. 2. Raise and support vehicle. 3. Disconnect sensor electrical connector. 4. Remove sensor mounting bolt. 5. Carefully remove sensor in a rocking motion with two small screwdrivers. 6. Remove sensor from vehicle. 7. Inspect sensor O-ring. Crankshaft Position Sensor Crankshaft Position Sensor Installation INSTALLATION 1. Apply a small amount of clean motor oil to sensor o-ring. 2. Install the sensor into the cylinder block with a slight rocking motion. Do not twist sensor into position as damage to sensor may result. Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 375 16. Remove clutch master cylinder rubber seal from dash panel. 17. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Tighten cap on clutch fluid reservoir to avoid spillage during installation. 2. Position cylinders, connecting lines and reservoir in vehicle engine compartment. 3. Lubricate cylinder seal with liquid dish soap to ease installation. Then seat seal in dash and around cylinder. 4. Insert clutch master cylinder in dash panel. Rotate cylinder 45° clockwise to lock it in place. 5. If cylinder seal is hard to seat, unlock cylinder and reseat seal if necessary. Then lock cylinder afterward. 6. Position clutch fluid reservoir on dash panel and install reservoir screws. Tighten screws to 5 Nm (40 inch lbs.) torque. 7. Install reservoir mounting bracket on dash panel, if removed. 8. Install replacement bushing on clutch pedal pin if necessary. 9. Install clutch master cylinder push rod on clutch pedal pinch Secure rod with wave washer, flat washer and retainer ring. 10. Connect clutch pedal position (interlock) switch wires. 11. Install locating clip in clutch master cylinder mounting bracket. 12. Raise vehicle. 13. Install slave cylinder. Be sure cap at end of cylinder rod is seated in release lever. Check this before installing cylinder attaching nuts. 14. Install and tighten slave cylinder attaching nuts to 23 Nm (200 inch lbs.) torque. 15. Lower vehicle. 16. If new linkage has been installed, remove plastic shipping stop from master cylinder push rod. Do this after installing slave cylinder and before operating linkage. 17. Operate linkage several times to verify proper operation. Page 718 Fig.5 Instrument Panel Splices (Part 1 Of 2) Page 899 Crankshaft Position Sensor: Locations Crankshaft Position Sensor Location The Crankshaft Position Sensor is mounted on the right side of engine block, behind the exhaust manifold. Page 405 Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes Chipped Electrode or Insulator Spark Plug: Testing and Inspection Chipped Electrode or 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. Page 402 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. Refer to the wiring diagrams. Differential Assembly Front Differential Assembly Page 957 8D - 36 Locations Page 692 Drive-Third Gear (Converter Clutch Applied) Page 943 5. From under the left front wheel opening, remove the two nuts that secure the forward end of the battery tray. 6. From the engine compartment, remove the two nuts and two bolts that secure the battery tray to the vehicle. Page 717 Fig.4 Door Wiring Splices Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test 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 filter/fuel pressure regulator. 1. Engine OFF. Disconnect the fuel inlet line at fuel rail. The fuel line-to-fuel rail connection is made at the rear of the engine. Remove air cleaner housing before tool connection. Connecting Adapter Tool 2. Connect Fuel Line Pressure Test Adapter Tool number 6539 (5/16 in.), or Adapter Thol number 6631 (3/8 in.) between the disconnected fuel line and fuel rail. Adapter Tool connection is made at rear of engine. 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on either tool 6631 or 6539. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 241-310 kPa (35-45 psi). 6. Shut engine off. 7. Pressure should not fall below 24 psi for five minutes. 8. If pressure falls below 24 psi, it must determined if a fuel injector, the fuel module mounted fuel pressure regulator or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Checking for fuel injector leakage: Clamp off the rubber hose portion of either tool 6539 or 6631 between the disconnected fuel tube (line) and test port inlet. If pressure now holds at or above 24 psi, a fuel injector or the fuel rail is leaking. 12. Checking for fuel pressure regulator or fuel tube leakage: Clamp off the rubber hose portion of either tool 6539 or 6631 between the fuel rail and test port inlet. If pressure now holds at or above 24 psi, a leak can be found at a fuel tube/line. If no leaks are found at fuel tubes or lines, replace the fuel filter/fuel pressure regulator. Page 418 Left Door Connector (Part 2 Of 2) Page 550 Power Door Locks (Part 2 Of 2) Page 529 Overhead Map Lamp Accessory Drive Belt - Noisy/Damaged Drive Belt: Customer Interest Accessory Drive Belt - Noisy/Damaged NO: 09-04-98 GROUP: Engine DATE: Sep. 25, 1998 SUBJECT: Accessory Drive Belt Noise Or Damage/Crank Pulley Bolt Loose MODELS: 1994 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the accessory drive belt becomes damaged on the inboard edge. Customers may explain the problem as belt noise. This may be caused by the crank pulley loosening on the crank and causing a misalignment. DIAGNOSIS: Inspect the accessory drive belt for fraying or unusual wear on the inboard edge. If wear is noted, inspect the crank pulley bolt for looseness and the crank pulley for misalignment. Sight the crank pulley with other accessory drives or use a straight edge to detect misalignment. If the crank pulley is misaligned or bolt is loose, perform the Repair Procedure. PARTS REQUIRED: 1 53041067 Belt, Accessory Drive 1994 - 1996 Models W/AC Federal 1 53041163 Belt, Accessory Drive 1994 - 1996 Models W/AC California 1 53041068 Belt, Accessory Drive 1994 - 1996 Models WO/AC Federal 1 53041164 Belt, Accessory Drive 1994 - 1996 Models WO/AC California 1 53041116 Belt, Accessory Drive 1997 - 1999 Models WO/AC Federal 1 53041117 Belt, Accessory Drive 1997 - 1999 Models WO/AC California 1 53041115 Belt, Accessory Drive 1997 - 1999 Models W/AC All 1 04318032 Adhesive, Stud and Bearing Mount REPAIR PROCEDURE: This bulletin involves removing the crank pulley bolt, checking the press fit of the pulley, reinstalling the bolt using thread locker, and replacing the accessory drive belt. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt following service manual procedures. 3. Drain and remove the radiator following all service manual warnings/cautions and procedures. NOTE: DRAIN THE COOLANT INTO A CLEAN DRAIN PAN. 4. Remove the bolt attaching the crankshaft pulley damper to the crankshaft. 5. Using your hands, pull on the crankshaft pulley damper to test the press fit to the crank shaft. The pulley should be tight and not come off the crank with hand pressure. NOTE: IF THE CRANK PULLEY DAMPER IS LOOSE (NO PRESS FIT) REPLACE THE CRANK PULLEY DAMPER WITH P/N 53020776. 6. Use Miller Tool C-3688 and fully press the crankshaft pulley damper onto the crankshaft. 7. Add thread locker p/n 04318032 to the end 3 or 4 threads of the crank pulley bolt. Page 924 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Page 977 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Description and Operation Hose/Line HVAC: Description and Operation REFRIGERANT LINE The refrigerant lines are used to carry the refrigerant between the various air conditioning system components. A barrier hose design is used for the air conditioning system on this vehicle. The ends of the refrigerant hoses are made from lightweight aluminum, and use braze-less fittings. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Page 959 8D - 38 Page 612 Front End Lighting With Daytime Running Lamps (Part 2 Of 2) Page 236 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Locations Left Impact Sensor Page 589 Airbag System (Part 1 Of 2) Page 146 Air Bag Control Module: Description and Operation OPERATION The deceleration or g-force resulting from the impact of a front-end collision causes the safing sensor inside of the Airbag Control Module (ACM) to be closed. As soon as one front sensor and the safing sensor are closed, an electrical charge is sent to the air bag module(s). This causes the inflators to be actuated, thus deploying the air bags. The total time from the closure of the switches to deployment and deflation of the air bag is 1/10th of a second. SELF DIAGNOSTIC FUCTIONS Whenever the ignition key is turned to the "RUN" or "START" position, the air bag control module (ACM) performs a lamp check by turning the AIR BAG warning lamp ON. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The air bag system is monitored by the ACM. The ACM monitors critical input and output circuits within the air bag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the air bag system to the technician through the DRB via the CCD bus. Page 432 Front End Lighting Without Daytime Running Lamps (Part 1 Of 2) Page 480 ALPHABETICAL INDEX (Part 6 Of 6) Page 608 Joint Connector(C) Wiring (Part 1 Of 2) Page 308 Fig. 8 5. Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R". Retape the wiring bundle as necessary. Fig. 8 6. For vehicles WITHOUT headlamp switch connector or terminal heat damage: Remove the PINK w/RED TRACER wire from location "B2" and the BLACK w/YELLOW TRACER wire from location "R" of the headlamp switch connector using a small screwdriver, Miller Special Tool # 8197 or equivalent. Fig. 9 7. Insert the wire terminals that were originally in locations "B2" and "R" of the headlamp wiring connector into the supplied 2-way wiring connector. Insert the PINK wired TRACER wire into the (+) cavity. Insert the BLACK w/YELLOW TRACER wire into the (-) cavity. Secure the terminals with the provided 2-way wedge. Page 758 Camshaft Position Sensor INSTALLATION (Used Sensor) CAUTION: When installing used camshaft position sensor, the sensor depth must be adjusted to prevent contact with cam gear. 1. Inspect face of the sensor. If any of the rib material remains, it must cut down flush to face of sensor with a razor knife. Remove only enough of the rib material to make face flat. Do not remove more material than necessary as damage to sensor may result. NOTE: Never use an electric grinder on a camshaft position sensor. 2. Obtain a peel-and-stick paper spacer. These special spacers are used as a tool to set sensor depth. 3. Clean face of sensor and apply paper spacer. 4. Apply a small amount of clean motor oil to sensor o-ring. 5. Install the sensor into the timing cover with a slight rocking motion until paper spacer contacts the cam gear. 6. Scratch a scribe line into timing cover to indicate sensor depth. 7. Remove sensor from timing cover. 8. Remove paper spacer from the sensor. 9. Again, apply a small amount of clean motor oil to sensor o-ring. 10. Install the sensor into the timing cover with a slight rocking motion until sensor is aligned with scribe line. 11. Install sensor mounting bolt and torque to 6 Nm (50 in-lbs). 12. Connect sensor electrical connector. Locations Horn Relay: Locations Power Distribution Center Power Distribution Center Engine Compartment - Flutter Noise on Deceleration Air Injection Pump: All Technical Service Bulletins Engine Compartment - Flutter Noise on Deceleration NO: 18-27-95 GROUP: Vehicle Performance DATE: Aug. 18, 1995 SUBJECT: Flutter Noise From Engine Compartment THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-28-94, DATED DEC. 23, 1994, WHICH SHOULD BE NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (81-699-95054). THE AIR FILTER HOUSING NO LONGER CONTAINS A GREEN MARK. THE CHANGE IS MARKED WITH **ASTERISKS**. MODELS: 1994 - 1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Flutter noise emitted from the engine compartment on closed throttle decelerations/light acceleration between 1500 to 1800 RPM. DIAGNOSIS: Test drive vehicle steadily accelerating. Take foot off throttle and listen for flutter or popping noise. If noise is found, perform repair procedure. PARTS REQUIRED: 1 4324506 Air Pump - Air Filter Housing REPAIR PROCEDURE: This bulletin involves the replacement of the existing air pump. ** The air filter housing is no longer marked with a green mark on the main part label, all parts are the updated version.** 1. Remove the silencer tube at the housing. 2. Remove the air inlet tube at the housing. 3. Remove the rubber cap. 4. Remove the mounting bracket strap bolt. 5. Note the position of the tube fittings before removing filter housing assembly from bracket. Gently bend the strap and remove filter housing assembly. 6. Install the air filter housing assembly to the mounting bracket. 7. Install and tighten strap bolt. 8. Install air inlet tube, silencer tube and cap at filter housing. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 25-01-08-90 0.2 Hrs. FAILURE CODE: P8 - New Part Page 1199 Coolant: Specifications System Capacity System Capacity Coolant capacity 24 qt (US) Page 478 ALPHABETICAL INDEX (Part 4 Of 6) Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 843 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 689 Drive-First Gear Page 83 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 396 Air Door Actuator / Motor: Service and Repair Panel/Defrost Door Actuator Replacement Fig 51 Panel-Defrost Door Actuator PANEL-DEFROST DOOR ACTUATOR Removal 1. Remove the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 2. Disconnect the vacuum line from the panel-defrost door actuator. 3. Separate the panel-defrost door crank arm from the door pivot pin. 4. Remove the screws that secure the panel-defrost door actuator to the heater-A/C housing. 5. Remove the panel-defrost door actuator from the heater-A/C housing. Installation 1. Install the panel-defrost door actuator on the heater-A/C housing. 2. Install and tighten the screws that secure the panel-defrost door actuator to the heater-A/C housing. 3. Press the panel-defrost door crank arm onto the door pivot pin. 4. Connect the vacuum line to the panel-defrost door actuator. 5. Install the heater-A/C housing. Page 333 13. Pull the headlamp switch control knob out to the ON position stop. 14. Depress the switch knob and shaft release button on the bottom of the switch assembly and then pull the switch knob and shaft out of the switch. Fig. 5 15. Remove the three screws that secure the headlamp switch bezel to the switch mounting bracket and then remove the bezel. Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket from the switch assembly. Discard the switch assembly. B. Install the Parklamp Circuit Overlap Harness: 1. Remove the wedge from the 9-way headlamp switch wiring connector. Fig. 6 2. Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage. Page 700 Reverse Caster and Camber Adjustment Alignment: Service and Repair Caster and Camber Adjustment Camber Caster is preset by the manufacturer with no provision for adjustment. Refer to "Front Wheel Alignment Specifications" in this chapter when checking camber due to suspension damage or suspected misalignment. Caster Refer to "Front Wheel Alignment Specifications" in this chapter when checking caster. If caster is not in the acceptable range, record measurement. Caster can be adjusted by rotating cams on lower suspension arm. Page 678 Intermittent Wiper System (Part 1 Of 2) Page 172 57 Page 527 Cigar Lighter And Glove Box Lamp Page 931 Page 389 8. Remove bushing from passenger side of pedal (Figure 1). 9. Lubricate shaft bores in bracket and pedal with Mopar Multi-mileage Lube (P/N 4318063). 10. Install wave washer (P/N 52009582) onto bushing, then install bushing back into pedal. NOTE: THE BRAKE PEDAL SHOULD HAVE TWO BUSHINGS (ONE ON EACH END OF THE SHAFT BORE). REPLACE ALL DAMAGED OR MISSING BUSHINGS WITH BUSHING P/N 4294639. 11. Apply liberal quantity of Mopar Multi-mileage Lube to pedal shaft and to pedal bushings. 12. Position brake pedal in mounting bracket. 13. From passenger side, slide pedal shaft into bracket and through pedal. 14. Push pedal shaft out driver side of mounting bracket just enough to allow installation of retaining E-clip. 15. Install booster push rod on brake pedal. Secure push rod to pedal with washer and retaining clip. 16. Install stop lamp switch. 17. Install knee bolster. 18. Install stop lamp fuse. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-50-01-92 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Page 731 Fig.8 Steering Column Wiring Locations Blower Motor Relay: Locations Fig 39 Blower Motor Relay Removal/Installation The relay is located in the passenger compartment on the stop lamp switch bracket. The stop lamp switch bracket is secured to the inboard side of the pedal support bracket under the driver side of the instrument panel. The relay case includes a molded-in plastic slot that snaps over the blade-type relay mount on the stop lamp switch bracket. Page 55 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 351 13. Pull the headlamp switch control knob out to the ON position stop. 14. Depress the switch knob and shaft release button on the bottom of the switch assembly and then pull the switch knob and shaft out of the switch. Fig. 5 15. Remove the three screws that secure the headlamp switch bezel to the switch mounting bracket and then remove the bezel. Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket from the switch assembly. Discard the switch assembly. B. Install the Parklamp Circuit Overlap Harness: 1. Remove the wedge from the 9-way headlamp switch wiring connector. Fig. 6 2. Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage. Page 631 Fender And Tailgate Lamps (Dual Rear Wheels) Specifications Throttle Position Sensor: Specifications Mounting Bolt Torque .......................................................................................................................... .................................................... 7 Nm (60 in. lb.) Page 383 8. Remove bushing from passenger side of pedal (Figure 1). 9. Lubricate shaft bores in bracket and pedal with Mopar Multi-mileage Lube (P/N 4318063). 10. Install wave washer (P/N 52009582) onto bushing, then install bushing back into pedal. NOTE: THE BRAKE PEDAL SHOULD HAVE TWO BUSHINGS (ONE ON EACH END OF THE SHAFT BORE). REPLACE ALL DAMAGED OR MISSING BUSHINGS WITH BUSHING P/N 4294639. 11. Apply liberal quantity of Mopar Multi-mileage Lube to pedal shaft and to pedal bushings. 12. Position brake pedal in mounting bracket. 13. From passenger side, slide pedal shaft into bracket and through pedal. 14. Push pedal shaft out driver side of mounting bracket just enough to allow installation of retaining E-clip. 15. Install booster push rod on brake pedal. Secure push rod to pedal with washer and retaining clip. 16. Install stop lamp switch. 17. Install knee bolster. 18. Install stop lamp fuse. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-50-01-92 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 221 Temperature Sensor (Gauge): Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 358 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 ADDITIONAL INFORMATION If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter SAFETY RECALL TO REPLACE YOUR TRUCK'S HEADLAMP SWITCH AND INSTALL A RELAY WIRING HARNESS Dear Dodge Ram 3500 Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1994 through 1997 Dodge Ram 3500 Series trucks. The problem is... Driving your Ram truck (identified on the enclosed form) with the lights on for an extended time frame can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. What DaimlerChrysler and your dealer will do... Daimlerchrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the headlamp switch and do install a relay wiring harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your saftey... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call l-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Locations Battery Wiring Page 466 Infinity Stereo Radio System (Part 1 Of 2) Page 763 120° F .................................................................................................................................................. ........................................ 1.25 V HOT CURVE (Reference voltage routed to sensor through PCM internal resistance of 10 k ohm) Temperature ........................................................................................................................................ ........................................ Voltage 110° F .................................................................................................................................................. ........................................ 4.20 V 120° F .................................................................................................................................................. ........................................ 4.00 V 130° F .................................................................................................................................................. ........................................ 3.77 V 140° F .................................................................................................................................................. ........................................ 3.60 V 150° F .................................................................................................................................................. ........................................ 3.40 V 160° F .................................................................................................................................................. ........................................ 3.20 V 170° F .................................................................................................................................................. ........................................ 3.02 V 180° F .................................................................................................................................................. ........................................ 2.80 V 190° F .................................................................................................................................................. ........................................ 2.60 V 200° F .................................................................................................................................................. ........................................ 2.40 V 210° F .................................................................................................................................................. ........................................ 2.20 V 220° F .................................................................................................................................................. ........................................ 2.00 V 230° F .................................................................................................................................................. ........................................ 1.80 V 240° F .................................................................................................................................................. ........................................ 1.62 V 250° F .................................................................................................................................................. ........................................ 1.45 V Page 307 Fig. 7 ^ Carefully inspect the connector and terminals B1, B2, R and H for signs of damage from overheating (melted connector and/or discolored terminal). If any one of these terminals shows signs of damage, ALL FOUR of these terminals MUST be replaced. Continue with Step 3. ^ Carefully inspect the connector and all other terminals. If any terminals in addition to B1, B2, R and H are damaged, terminals B1, B2, R, H and any other damaged terminals MUST be replaced. Continue with Step 3. ^ If there is no indication of heat damage, continue with Step 6. 3. For vehicles with headlamp switch wire terminal and connector heat damage: Remove any damaged wire terminals from the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent. If the connector is also damaged and cannot be reused, remove all wires and discard the connector. 4. Replace any damaged wires as determined in Step 2 as follows: a. Cut the electrical tape and remove the affected wire(s) from the bundle. b. Cut off the damaged wire approximately 10 inches from the terminal. NOTE: Stagger the wire splice locations by about 1/2 inch. c. Remove about 1 inch of insulation from the end of the wire. d. Remove about l inch of insulation from the end of the matching color and gauge wire and terminal provided in the parts package. e. Slip one piece of the provided heat shrink tubing over the new wire end. f. Twist the exposed wire ends of the harness wire and the replacement wire end together. g. Solder the twisted wire ends together using rosin core solder. CAUTION: All wiring splices must be soldered or future circuit failure may occur. h. Slide the heat shrink tubing over the wire splice and heat the tubing until the tubing shrinks tightly around the wire and sealant comes out both ends of the tubing. i. Repeat Steps A - H for all other damaged wires as necessary. Page 893 Camshaft Position Sensor: Testing and Inspection Sensor Connector 1. Disconnect the sensor pigtail harness from the main engine wiring harness connector. 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Page 178 173 Adjustments Valve Clearance: Adjustments These engines are equipped with hydraulic lifters with no provision for adjustment. Page 501 Fuel Injection Ignition System (Part 10 Of 10) Testing and Inspection Wiper Switch: Testing and Inspection Two Speed Wiper Switch Continuity Chart Page 624 Cargo And Dome Lamps Page 698 Park Page 789 Engine Wiring Connector Locations Page 751 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 427 84-way Connector Headlamp And Dash To Instrument Panel Wiring (Part 2 Of 2) Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 186 201 Page 609 Joint Connector(C) Wiring (Part 2 Of 2) Page 688 Park/Neutral Locations 1994 - 1999 8.0L (488) Page 102 Based on these inputs, the PCM will: - Monitor crankshaft position sensor. If no signal is received within 3 seconds, the PCM will shut down the fuel injection system. - Supply the injectors with a ground path, firing all injectors until the PCM determines crankshaft position. - Determine proper ignition timing. Engine Warm-Up Mode This is an OPEN LOOP mode. During engine warm-up, the Powertrain Control Module (PCM) receives input from: - Battery voltage - Crankshaft position (CKP) sensor - Engine coolant temperature (ECT) sensor Intake air temperature (IAT) sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position (CMP) sensor - A/C select switch Based on these inputs the PCM will: - Apply voltage to the injectors. The PCM then controls injection sequence and pulse width by switching individual injector ground paths on and off. - Adjust engine idle speed through the IAC motor. - Adjust ignition timing. - Operate A/C Compressor Clutch relay (if selected). - Operate the Up-Shift indicator light. - Begin to monitor oxygen sensor. When engine is at operating temperature, the system will leave warm up mode and go into closed loop operation. Idle Mode This is a CLOSED LOOP mode. With engine idling at operating temperature, the Powertrain Control Module (PCM) receives inputs from: - Air Conditioning Control Position - Battery voltage - Camshaft position (CMP) sensor - Engine coolant temperature (ECT) sensor - Manifold Absolute Pressure (MAP) sensor - Intake air temperature (IAT) sensor - Crankshaft position (CKP) sensor - Throttle Position Sensor (TPS) Heated oxygen sensor (HO2S) Based on these inputs the PCM will: - Apply voltage to the injectors. The PCM then controls injection sequence and pulse width by switching individual injector ground paths on and off. - Monitor oxygen sensors and fine tune air/fuel ratio by varying injector pulse width. - Adjust engine idle speed through the IAC motor. - Adjust ignition timing. - Operate A/C Compressor Clutch relay (if selected). Ignition Switch Off Mode When the ignition switch is OFF the Powertrain Control Module (PCM) will stop operating the: - Fuel injectors - Ignition coil - Automatic shutdown (ASD) relay - Fuel pump relay. Ignition Switch On This is an OPEN LOOP mode. When the sequential multi-point fuel injection (SFI) system is activated by the ignition switch, the following actions occur: Page 495 Fuel Injection Ignition System (Part 4 Of 10) Page 168 45 Page 556 Seatbelt Warning And Chime System (Bux Only) (Part 2 Of 2) Page 736 Battery Wiring Page 585 Right Door Connector (Part 2 Of 2) Page 456 Power Mirror System (Part 1 Of 2) Page 643 Fuel Injection Ignition System (Part 4 Of 10) Transfer Case - High Shift Effort When Cold Fluid - Differential: All Technical Service Bulletins Transfer Case - High Shift Effort When Cold NO.: 21-25-94 GROUP: Transmission DATE: Dec. 23, 1994 SUBJECT: High Effort when Shifting from 2WD High to 4WD High, in Cold Ambient Temperatures MODELS: 1994 - 1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO BR VEHICLES EQUIPPED WITH NP231 HD, NP241, OR NP241 HD TRANSFER CASE. SYMPTOM/CONDITION: High shift effort, condition occurs during cold weather operation while shifting the transfer case into 4WD High from the 2WD High mode. DIAGNOSIS: With vehicle cold (below 30 degrees F), shift transfer case from 2WD High to 4WD High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment. Reference appropriate Ram Truck Service Manual for transfer case shift linkage adjustment procedure. With vehicle still cold, attempt to shift from 2WD High to 4WD High at approximately 25 MPH. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4WD High mode for approximately 10 miles. Shift transfer case from 2WD High to 4WD High several times. Allow time between shifts to ensure synchronizer is out of the 4WD High mode before shifting. NOTE: AVOID SHARP TURNS ON HARD DRY SURFACES WHILE TESTING VEHICLE. If vehicle exhibits high shifting effort in cold weather operation (below 30 degrees F), but has reasonable effort and consistency after axle lube is warm, perform the front axle lubricant fill procedure listed. If Vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts require replacement in addition to the front axle lubricant change. PARTS REQUIRED: Specifications Spark Plug: Specifications Brand ................................................................................................................................................... .................................................................. Champion Part Number ........................................................................................................................................ .................................................................. RC9MC4 Gap ...................................................................................................................................................... ..................................................... 0.045 in. (1.4 mm) Tightening Torque ............................................................................................................................... ..................................................... 41 Nm (30 ft.lb.) Thread ................................................................................................................................................. ...................................................... 14mm, 3/4" reach Page 909 NOTE: Before tightening sensor mounting bolt, be sure sensor is flush to cylinder block. 3. Install sensor mounting bolt and torque to 8 Nm (70 in-lbs). 4. Connect sensor electrical connector. 5. Lower vehicle. Page 715 Fig.2 Cab Wiring Splices Page 371 Transfer Case Actuator: Testing and Inspection Page 404 Universal Joint, Drive/Propeller Shaft Exploded View Of Single Cardan Type Universal Joint System Illustration shows typical single Cardan type universal joints. Page 557 Seatbelt Warning And Buzzer System (Part 1 Of 2) Page 574 Engine Connector-C Page 494 Fuel Injection Ignition System (Part 3 Of 10) Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 907 Crankshaft Position Sensor: Testing and Inspection Sensor Connector 1. Disconnect the sensor pigtail harness from the main engine wiring harness connector. 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Page 428 84-way Connector Instrument Panel To Headlamp And Dash Wiring (Part 1 Of 2) Page 627 Headlamp Switch And Joint Connector(A) Wiring (Part 1 Of 2) Page 1104 Spark Plug: Service and Repair Removal and Installation NOTE: Be sure to note routing of secondary ignition cables. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECTION Inspect plug for: 1. Cracked or damaged threads or insulator 2. Worn or bent electrodes 3. Damaged gasket 4. Electrode wear or excessive carbon deposits INSTALLATION 1. Start plug in cylinder head by hand to prevent cross threading. 2. Torque spark plugs to 41 Nm (30 ft-lbs). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). Air Filter - Service Precautions Air Filter Element: Technical Service Bulletins Air Filter - Service Precautions NUMBER: 09-07-00 GROUP: Engine DATE: Apr. 7, 2000 SUBJECT: Air Filter Service MODELS: 1994 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 8.0L ENGINE. DISCUSSION: When servicing the air filter, it is important to ensure that the engine wiring harness is routed to the left (as viewed from the front of the engine) of the air filter housing attaching clip as shown in image. Failure to properly route the wiring harness may result in wire harness damage. POLICY: Information Only Diagram Information and Instructions Temperature Sensor (Gauge): Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Page 654 Stereo Radio System (Part 1 Of 2) Page 41 Compressor Clutch Relay: Testing and Inspection 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 75 +/-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 the Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 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 PDC fuse 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 block module 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. Page 809 Figures 1 & 2. 4. Verify that the wires are connected properly as listed in step 2. 5. All fault codes should be cleared using the ORB II/III (Scan Tool). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 25-01-70-97 0.5 Hrs. Sensor, Oxygen - Reroute Wires and Reconnect. 94-95 BR FAILURE CODE: WV - Wiring Misrouted Page 613 Front End Lighting Without Daytime Running Lamps (Part 1 Of 2) Distributor Drive Gear - Manual Revisions Distributor: Technical Service Bulletins Distributor Drive Gear - Manual Revisions NO.: 09-23-93 GROUP: Engine DATE: Dec. 31, 1993 SUBJECT: Service Manual Revision- Distributor Drive Gear Illustration Corrected MODELS: 1994 (AB) Ram Van/Wagon 1994 (AN) Dakota/Dakota Cab & Chassis 1994 (BR) Ram Pickup, Chassis Cab This Technical Service Bulletin revises service manual pages. POLICY: Information Only Diagram Information and Instructions Relay Box: Diagram Information and Instructions Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Splice Location Symbol Identification Wiring Splice Examples Splice locations are indicated in the diagrams by a diamond with a splice circuit code within it (example 1). If there is more than one splice per circuit a small box will be connected to it with the splice number in it (example 2). To locate a splice in the wiring harness determine the splice number from the diagrams then refer to Locations/Splices. This section shows the general location of the splice in the harness. Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Page 825 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 687 Power Distribution Center Page 338 6. Connect the single wire connector from the overlay harness to the ground terminal on the headlamp switch assembly. Fig. 4 7. Tuck the relay pack into the instrument panel pocket on the left side between the demister duct and the HVAC duct and then install the headlamp switch into the instrument panel. Tighten the three attaching screws securely. 8. Connect the lighter wiring connector. 9. Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel. Fig. 3 10. Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel. Fig. 2 11. Install the ash receiver bracket. Tighten the bracket screws securely. 12. Install the ash receiver. Page 605 Headlamp Switch And Joint Connector(A) Wiring (Part 1 Of 2) Page 588 Power Mirror Switch Connector Page 1097 Spark Plug: Testing and Inspection Electrode Gap Bridging Spark Plug Inspection ^ 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, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures. Page 874 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 336 Fig. 9 8. Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness. Fig. 8 9. Insert the two wire terminals from the overlay harness into the headlamp switch connector. Insert the PINK wIRED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity. 10. Secure the wire terminals in the headlamp switch connector with the provided 9-way wedge. C. Install the Headlamp Switch Assembly: 1. Install the headlamp switch bezel bracket on the new switch assembly. 2. Install the headlamp switch bezel on the mounting bracket. Tighten the three (3) mounting screws securely. Fig. 10 Page 620 Center High Mounted Stop Lamp Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Test Port Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Electrical Specifications Intake Air Temperature Sensor: Electrical Specifications Temperature VS. Voltage Curve Temperature Voltage .............................................................................................................................................................. ........................................ -20° F 4.81 V .............................................................................................................................................................. .............................................. 0° F 4.70 V .............................................................................................................................................................. ................................................ 20° F 4.47 V .............................................................................................................................................................. ............................................... 40° F 4.11 V .............................................................................................................................................................. ............................................... 60° F 3.67 V .............................................................................................................................................................. ............................................... 80° F 3.08 V .............................................................................................................................................................. ............................................... 100° F 2.51 V .............................................................................................................................................................. .............................................. 120° F 1.97 V .............................................................................................................................................................. .............................................. 140° F 1.52 V .............................................................................................................................................................. .............................................. 160° F 1.15 V .............................................................................................................................................................. .............................................. 180° F 0.86 V .............................................................................................................................................................. ............................................. 200° F 0.65 V .............................................................................................................................................................. ............................................. 220° F 0.48 V .............................................................................................................................................................. ............................................. 240° F 0.35 V .............................................................................................................................................................. ............................................. 260° F 0.28 V .............................................................................................................................................................. ............................................. Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications Brake Pedal - Rattle While Driving Brake Pedal Assy: Customer Interest Brake Pedal - Rattle While Driving NO: 05-08-96 GROUP: Brakes DATE: Sept. 13, 1996 SUBJECT: Brake Pedal Rattle MODELS: 1994 - 1996 (BR) Ram Truck SYMPTOM/CONDITION: Customers may complain of a rattle coming from the brake pedal area while driving. DIAGNOSIS: Drive the vehicle on a rough surfaced road. If a rattle is heard coming from the brake pedal area and is eliminated when pressure is applied to the side of the brake pedal, perform the following Repair Procedure. PARTS REQUIRED: 1 52009582 Wave Washer, Brake Pedal REPAIR PROCEDURE: This bulletin involves removing the brake pedal and installing a wave washer between the brake pedal and the brake pedal bushing. 1. Remove stop lamp fuse (fuse # 20) 2. Remove the knee bolster. 3. Remove stop lamp switch from mounting bracket, turning counter-clockwise. 4. Remove clip and washer attaching booster push rod and slide push rod off pedal. 5. Push shaft toward driver side of bracket just enough to expose left side E-clip then, remove E-clip with a flat blade screwdriver. 6. Push pedal shaft out of passenger side of bracket. 7. Remove brake pedal and pedal shaft from vehicle. Air Filter - Service Precautions Air Filter Element: Technical Service Bulletins Air Filter - Service Precautions NUMBER: 09-07-00 GROUP: Engine DATE: Apr. 7, 2000 SUBJECT: Air Filter Service MODELS: 1994 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 8.0L ENGINE. DISCUSSION: When servicing the air filter, it is important to ensure that the engine wiring harness is routed to the left (as viewed from the front of the engine) of the air filter housing attaching clip as shown in image. Failure to properly route the wiring harness may result in wire harness damage. POLICY: Information Only Page 667 Fuse Application Chart (Part 3 Of 3) Page 593 Rear Wheel ABS System (Part 1 Of 2) Page 610 Printed Circuit Board Page 1154 Drive Belt: Service and Repair Removal 1. Attach a suitable wrench to the pulley mounting bolt of the automatic tensioner. 2. Rotate tensioner assembly clockwise until tension has been relieved. 3. Remove belt from vehicle. Installation 1. Position drive belt over all pulleys except idler pulley. 2. Attach a suitable wrench to the pulley mounting bolt of the automatic tensioner. 3. Rotate wrench clockwise, place belt over idler pulley then allow tensioner to rotate back into place. Ensure belt is properly seated on all pulleys. 4. Check belt indexing marks as outlined under "Belt Tensioner Replacement." 1993-96 5.9L/V8-360HD & 8.0L/V10-488 ENGINES Removal 1. Attach a wrench to pulley mounting bolt of automatic tensioner. The threads on this bolt are left-hand. 2. Release tension from belt by rotating tensioner counterclockwise. When all belt tension has been released remove belt from tensioner first, then other pulleys. Installation 1. Position drive belt on all pulleys except tensioner pulley. 2. Attach a wrench to pulley bolt of tensioner, then rotate wrench counterclockwise. 3. Place belt over tensioner pulley, let tension rotate back into place, then ensure belt is properly seated on all pulleys. Page 670 Engine Oil Pressure And Engine Coolant Temp. System Page 487 Ignition Switch (Part 2 Of 2) Page 844 Throttle Position Sensor: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 94 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 546 Air Conditioning And Heater System (Part 2 Of 2) Page 703 Drive Third Gear Page 707 Manual Second (2) Page 945 NOTE: Do not remove the tape that secures the sensor wire harness to the connector. 12. To install, plug in the sensor wire harness connector to the impact sensor. 13. Mount the sensor (arrow pointed forward) using the three screws provided with the new sensor. Tighten the screws to 5 to 6 N.m (45 to 55 in. lbs.). 14. Plug the wire harness connector into the speed control servo. 15. Install the battery tray. Tighten all of the battery tray mounting hardware to 16 N.m (140 in. lbs.). 16. Install the battery in the vehicle, making sure that the battery is properly positioned in the battery tray 17. If equipped, install the battery heat shield. 18. Install the battery holddown clamp. Be certain that the holddown is properly positioned on the battery. Tighten the holddown bolts to 4 N.m (35 in. lbs.). 19. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Page 661 Seatbelt Warning And Buzzer System (Part 2 Of 2) Page 425 Joint Connector(C) Page 832 Oxygen Sensor: Testing and Inspection Sensor Functional Test NOTES: ^ This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. ^ Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. CAUTION: Verify DVOM is set to read VOLTS only (not ohms). Verify external voltage is not applied to the sensor lead, as damage to the sensor may occur. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2500 RPM for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor connector. Connect the positive lead of the DVOM to the oxygen sensor. 3. Create a full lean condition, by removing a large vacuum hose, for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a full rich condition, by introducing propane into intake manifold, for 10 seconds. Voltage should increase to 0.8 volt or less and remain there. 5. Verify that engine is at operating temperature and O2 sensor heating element (if equipped) is functioning. See Sensor Heating Element Test. See: Sensor Heating Element Test 6. If engine is at operating temperature and heating element passes, but the sensor fails to vary according to the test steps above, the sensor is defective. 7. Connect the oxygen sensor and clear codes. Page 856 Vehicle Speed Sensor (typical) Page 579 Anti-Lock Brake System Controller Component Locations Vehicle Speed Sensor (typical) Page 444 Stop/Turn And Hazard Flasher System Page 475 ALPHABETICAL INDEX (Part 1 Of 6) Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center Power Distribution Center Page 660 Seatbelt Warning And Buzzer System (Part 1 Of 2) Page 453 Horn System Page 960 8D - 38A Page 393 24-29 Page 584 Right Door Connector (Part 1 Of 2) Page 696 Manual First Gear (1) Page 408 Engine Connector-B Page 460 Power Door Locks (Part 2 Of 2) Page 555 Seatbelt Warning And Chime System (Bux Only) (Part 1 Of 2) Page 933 ABS Control Module Connector Anti-Lock Brake System Controller Page 72 Relay Box: Diagnostic Aids When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory 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. Refer to the wiring diagrams. Page 238 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Accessory Drive Belt - Noisy/Damaged Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Noisy/Damaged NO: 09-04-98 GROUP: Engine DATE: Sep. 25, 1998 SUBJECT: Accessory Drive Belt Noise Or Damage/Crank Pulley Bolt Loose MODELS: 1994 - 1999 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN 8.0L ENGINE. SYMPTOM/CONDITION: Some vehicles may exhibit a condition where the accessory drive belt becomes damaged on the inboard edge. Customers may explain the problem as belt noise. This may be caused by the crank pulley loosening on the crank and causing a misalignment. DIAGNOSIS: Inspect the accessory drive belt for fraying or unusual wear on the inboard edge. If wear is noted, inspect the crank pulley bolt for looseness and the crank pulley for misalignment. Sight the crank pulley with other accessory drives or use a straight edge to detect misalignment. If the crank pulley is misaligned or bolt is loose, perform the Repair Procedure. PARTS REQUIRED: 1 53041067 Belt, Accessory Drive 1994 - 1996 Models W/AC Federal 1 53041163 Belt, Accessory Drive 1994 - 1996 Models W/AC California 1 53041068 Belt, Accessory Drive 1994 - 1996 Models WO/AC Federal 1 53041164 Belt, Accessory Drive 1994 - 1996 Models WO/AC California 1 53041116 Belt, Accessory Drive 1997 - 1999 Models WO/AC Federal 1 53041117 Belt, Accessory Drive 1997 - 1999 Models WO/AC California 1 53041115 Belt, Accessory Drive 1997 - 1999 Models W/AC All 1 04318032 Adhesive, Stud and Bearing Mount REPAIR PROCEDURE: This bulletin involves removing the crank pulley bolt, checking the press fit of the pulley, reinstalling the bolt using thread locker, and replacing the accessory drive belt. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belt following service manual procedures. 3. Drain and remove the radiator following all service manual warnings/cautions and procedures. NOTE: DRAIN THE COOLANT INTO A CLEAN DRAIN PAN. 4. Remove the bolt attaching the crankshaft pulley damper to the crankshaft. 5. Using your hands, pull on the crankshaft pulley damper to test the press fit to the crank shaft. The pulley should be tight and not come off the crank with hand pressure. NOTE: IF THE CRANK PULLEY DAMPER IS LOOSE (NO PRESS FIT) REPLACE THE CRANK PULLEY DAMPER WITH P/N 53020776. 6. Use Miller Tool C-3688 and fully press the crankshaft pulley damper onto the crankshaft. 7. Add thread locker p/n 04318032 to the end 3 or 4 threads of the crank pulley bolt. Page 622 Fender And Tailgate Lamps (Dual Rear Wheels) Component Locations Wheel Speed Sensor: Component Locations Wheel Speed Sensors / Tone Wheels Wheel Speed Sensors / Tone Wheels Wheel Speed Sensors / Tone Wheels Page 152 Starter Relay: Testing and Inspection Fig 3 Starter Relay Terminal Identification 1. Remove starter relay from relay center. 2. Check resistance between ground and ignition terminals. Resistance value between ground and ignition terminals should be 70-80 ohms for resistor relays and 81-91 ohms for diode relays. 3. Apply battery voltage to relay ignition terminal and connect ground terminal to ground. Continuity should exist between battery and solenoid terminals. If continuity does not exist, replace relay. Page 833 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test NOTES: ^ This test should be performed only after basic inspection, and ignition and fuel systems inspections are passed. ^ Only use a high input impedance Digital Volt Ohm Meter (DVOM) when testing components on computerized vehicles. ^ Verify DVOM is set to read OHMS only (not volts). Verify external voltage is not applied to the sensor lead, as inaccurate results will occur. TEST DESCRIPTION 1. Disconnect the oxygen sensor(s) electrical connector from the wiring harness 2. Connect DVOM across terminals 3 and 4 of the sensors electrical connector. Set to read OHMS. 3. Resistance value should be between 5 and 7 ohms. 4. Replace the sensor if the resistance reading is not within specifications or if the ohmmeter indicates infinite resistance. Page 632 Stop/Turn And Hazard Flasher System Page 222 Engine Oil Pressure And Engine Coolant Temp. System Page 721 Fig.8 Engine Compartment Splices (Part 2 Of 2) Page 511 Anti-Lock Brake System (Part 4 Of 4) Hissing/Suction Noise From Air Injection Pump Filter Air Injection Filter: All Technical Service Bulletins Hissing/Suction Noise From Air Injection Pump Filter NO: 25-01-97 GROUP: Emissions DATE: Apr. 18, 1997 SUBJECT: Hissing/Suction Noise Coming From Air Injection Pump Filter Inlet MODELS: 1994 - 1997 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 8.0L V-10 ENGINE. SYMPTOM/CONDITION: Hissing/Suction noise coming from the inlet air tube of the air injection pump filter. DIAGNOSIS: Start the engine and allow the engine to fully warm up. While the engine is idling, listen for a hissing/suction noise coming from the inlet air tube of the air injection pump filter. If an hissing/suction noise is heard, pinch off the air inlet tube of the air injection pump filter. If the noise disappeared when the tube was pinched off, perform the Repair Procedure. If the noise is still heard, further diagnosis is required. Refer to the 1997 Ram Truck Service Manual (Publication No. 81-370-7108), pages 25-22 through 25-25 for additional information regarding the air injection system. PARTS REQUIRED: 1 53031546 Tube, Inlet Air, Air Injection Pump Filter REPAIR PROCEDURE: This bulletin involves replacing the inlet air tube of the air injection pump with a revised part. 1. Remove the inlet air tube that is attached to the air injection pump's filter and discard tube. 2. Install the new inlet tube (p/n 53031546) for the secondary air injection pump filter onto the air injection pump filter. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 25-01-07-90 0.2 Hrs. FAILURE CODE: P8 - New Part Page 711 Power Distribution Center The Power Distribution Center is located in the engine compartment, on the left fender apron. Page 399 Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Fusible Link Color Code Page 58 Daytime Running Lamps Module Page 240 Engine Oil Pressure And Engine Coolant Temp. System Page 659 Seatbelt Warning And Chime System (Bux Only) (Part 2 Of 2) Page 725 Fig.2 Frame Wiring Page 20 Electronic Brake Control Module: Diagrams 4 Wheel ABS System Related Images Page 818 Oxygen Sensor: Mechanical Specifications Torque ................................................................................................................................................. ...................................................... 30 Nm (22 ft. lb.) Page 458 Power Mirror Switch Connector Page 237 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 202 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Page 709 Fig 11 Vacuum Circuits Page 212 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The sensor element extends into the coolant passage where it maintains constant contact with the engine coolant. The Powertrain Control Module (PCM) uses this sensor to measure the temperature of engine coolant. OPERATION The PCM sends out a reference voltage of approximately five (5) volts to the engine coolant temperature sensor. As coolant temperature changes, the internal resistance of the sensor will change, causing a varying voltage drop across the sensor. The PCM reads the voltage drop across the sensor as engine coolant temperature. Based on the amount of voltage drop at the coolant sensor, the PCM will, adjust the fuel injector pulse width (a cold engine will receive a longer pulse width, allowing for a richer mixture), compensate for condensation of fuel in the intake manifold, monitor and adjust engine warm-up speed, and advance ignition timing when the engine is cold. Page 119 Automatic Shut Down (ASD) Relay: Description and Operation PURPOSE The Automatic Shutdown (ASD) Relay supplies battery voltage to fuel pump relay, fuel injectors, ignition coil, and O2 sensor heating element, when energized by Powertrain Control Module (PCM). OPERATION The PCM energizes the ASD relay by supplying relay ground, when ignition switch is in START or RUN position and PCM is receiving a reference signal from the camshaft and crankshaft position sensors. When the ground is applied, the relay is energized, and voltage is allowed to flow to fuel pump, fuel injectors, ignition coil, generator field winding, and O2 sensor heating element. When PCM does not receive reference signal from ignition system, (indicating engine is not running), then the PCM interrupts relay ground circuit and no voltage is supplied to fuel pump, fuel injectors, ignition coil, generator field winding, and O2 sensor heating element. The PCM controls fuel pump relay and ASD relays simultaneously, through same ground circuit. Page 616 Rear Lighting (Part 2 Of 2) Page 500 Fuel Injection Ignition System (Part 9 Of 10) Page 562 Trailer Tow System And Ground Joint (Part 2 Of 2) Page 586 Overhead Console Connector Page 184 193 Page 753 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 448 84-way Connector Instrument Panel To Headlamp And Dash Wiring (Part 1 Of 2) Page 166 39 Page 493 Fuel Injection Ignition System (Part 2 Of 10) Page 895 Camshaft Position Sensor INSTALLATION (Used Sensor) CAUTION: When installing used camshaft position sensor, the sensor depth must be adjusted to prevent contact with cam gear. 1. Inspect face of the sensor. If any of the rib material remains, it must cut down flush to face of sensor with a razor knife. Remove only enough of the rib material to make face flat. Do not remove more material than necessary as damage to sensor may result. NOTE: Never use an electric grinder on a camshaft position sensor. 2. Obtain a peel-and-stick paper spacer. These special spacers are used as a tool to set sensor depth. 3. Clean face of sensor and apply paper spacer. 4. Apply a small amount of clean motor oil to sensor o-ring. 5. Install the sensor into the timing cover with a slight rocking motion until paper spacer contacts the cam gear. 6. Scratch a scribe line into timing cover to indicate sensor depth. 7. Remove sensor from timing cover. 8. Remove paper spacer from the sensor. 9. Again, apply a small amount of clean motor oil to sensor o-ring. 10. Install the sensor into the timing cover with a slight rocking motion until sensor is aligned with scribe line. 11. Install sensor mounting bolt and torque to 6 Nm (50 in-lbs). 12. Connect sensor electrical connector. Page 455 Automatic Day/Night Mirror Recall 99V024000: Possible Headlamp Switch Failure Headlight Switch: Recalls Recall 99V024000: Possible Headlamp Switch Failure Operation of the headlamps over an extended period of time can result in Headlamp switch failure, causing the headlamps or park lamps to go out. If the lights fail, a visibility problem could occur, increasing the risk of a vehicle crash. Dealers will replace the Headlamp switch including a relay in the park lamp wiring circuit. Owner notification began June 14, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 1065 14. Install the screw attaching the trim panel to the outside mirror frame. 15. Install the window crank, if equipped. 16. Perform Steps 3 through 1 5 to the other door trim panel. 17. Connect the battery negative cable(s) and reset the clock. 18. Roll the windows up. 1-WINDOW CRANK REMOVAL TOOL 2-WINDOW CRANK Figure 1 1-POWER MIRROR 2-SCREW 3-POWER MORROR CONTROL 4-SCREW 5-TRIM PANEL 6-DOOR LOCK BUTTON 7-POWER WINDOW HARNESS 8-POWER MIRRIR HARNESS Figure 2 Page 464 Stereo Radio System (Part 1 Of 2) Page 430 Front End Lighting With Daytime Running Lamps (Part 1 Of 2) Specifications Crankshaft Position Sensor: Specifications Torque ................................................................................................................................................. ....................................................... 8 Nm (70 in. lb.) Page 563 Center High Mounted Stop Lamp Page 525 Joint Connector(C) Wiring (Part 1 Of 2) Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Page 583 Left Door Connector (Part 2 Of 2) Hissing/Suction Noise From Air Injection Pump Filter Air Injection Filter: Customer Interest Hissing/Suction Noise From Air Injection Pump Filter NO: 25-01-97 GROUP: Emissions DATE: Apr. 18, 1997 SUBJECT: Hissing/Suction Noise Coming From Air Injection Pump Filter Inlet MODELS: 1994 - 1997 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 8.0L V-10 ENGINE. SYMPTOM/CONDITION: Hissing/Suction noise coming from the inlet air tube of the air injection pump filter. DIAGNOSIS: Start the engine and allow the engine to fully warm up. While the engine is idling, listen for a hissing/suction noise coming from the inlet air tube of the air injection pump filter. If an hissing/suction noise is heard, pinch off the air inlet tube of the air injection pump filter. If the noise disappeared when the tube was pinched off, perform the Repair Procedure. If the noise is still heard, further diagnosis is required. Refer to the 1997 Ram Truck Service Manual (Publication No. 81-370-7108), pages 25-22 through 25-25 for additional information regarding the air injection system. PARTS REQUIRED: 1 53031546 Tube, Inlet Air, Air Injection Pump Filter REPAIR PROCEDURE: This bulletin involves replacing the inlet air tube of the air injection pump with a revised part. 1. Remove the inlet air tube that is attached to the air injection pump's filter and discard tube. 2. Install the new inlet tube (p/n 53031546) for the secondary air injection pump filter onto the air injection pump filter. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 25-01-07-90 0.2 Hrs. FAILURE CODE: P8 - New Part Page 958 8D - 37 Page 187 205 Page 686 Fig.12 Fuse Block And Relay Bank Page 422 Cluster Connector-A Page 24 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes Anti-Lock Electronic Control Module PURPOSE All phases of anti-lock mode brake operation are monitored and controlled by the Controller Antilock Brake module (CAB). OPERATION The module operates independently from other electrical circuits in the vehicle. CAB input/output circuits include the system hydraulic valve, indicator lamps, and the speed sensor. Speed sensor inputs are continuously monitored and interpreted by the module. The module determines wheel speed and rate of deceleration from these inputs and activates the appropriate solenoid in the hydraulic valve when necessary. The module performs system diagnostic checks and contains a self test program. The program is activated when the ignition switch is turned to the ON position. - In this mode, the module checks indicator light operation, the system electrical circuits and the pressure limiting valve solenoids. The brake warning and anti-lock indicator lamps are illuminated for approximately two seconds during the system self test cycle. Page 671 Trailer Tow System And Ground Joint (Part 1 Of 2) Page 669 Power Distribution Center Starting System For infomation regarding diagrams for this system, please refer to Starting and Charging diagrams. See: Starting and Charging/Diagrams Page 468 Power Seat System Page 636 Power Mirror System (Part 2 Of 2) Locations Low Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. Page 296 Brake Switch Spark Plug Wire - Engine Miss and /or Rough Idle Ignition Cable: Customer Interest Spark Plug Wire - Engine Miss and /or Rough Idle NO: 18-09-95A GROUP: Vehicle Performance DATE: April 21, 1995 SUBJECT: Engine Miss and/or Rough Idle MODELS: 1994 - 1995 (BR) Ram Pickup THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-09-95 DATED MARCH 10, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE MARKED WITH **ASTERISKS**. Note: This Bulletin Applies To Vehicles Equipped With An 8.0L V10 Engine Built Prior to 2/14/94 (MDH 02-14-XX). SYMPTOM/CONDITION: Engine miss and/or rough idle may be experienced. The cause of the engine miss and/or rough idle may be the secondary ignition cables shorting at the coil boot. DIAGNOSIS: This condition will normally show NO fault codes. It may mislead the technician into diagnosing this problem as being related to a base engine component malfunction, such as stuck lifters or valve train problems. If the vehicle is brought in for service with vehicle performance complaints (rough idle, engine miss), and the DRB does not show any fault codes, check ignition cables for the date code of 1st quarter 1994 (1-94) or earlier. The date code will appear as follows: Note: Date coding is done quarterly on wires. example is given below. MOPAR ELECTRONIC SUPPRESSION GX 1-94 AATH GX = Material Code 1-94 = Date Code - Represents the 1st Quarter of 1994 AATH = Vendor Identification **Note: If the ignition cables are found to be dated the first quarter of 1994 (1/94) or earlier, they should be replaced with cables dated 2nd quarter (2/94) and later.** POLICY: Information Only Page 498 Fuel Injection Ignition System (Part 7 Of 10) Page 739 Fig.18 Engine Wiring Page 19 Rear Wheel Anti-Lock Control Module Connector Page 568 84-way Connector Instrument Panel To Headlamp And Dash Wiring (Part 1 Of 2) Page 490 Transmission Overdrive System (Part 2 Of 3) Page 1010 Fuel Pressure: Testing and Inspection Fuel Pressure Test Pressure Relief/Rollover Valve Fuel systems on gas powered engines are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is a mechanical device that is not controlled by the powertrain control module (PCM) or engine vacuum. With engine at idle speed, system fuel pressure should be approximately 241-310 kPa (35-45 psi). Fuel Pressure Test Port 1. Remove (unscrew) the protective plastic cap from the pressure test port on the fuel rail. This test port is located at the front of the engine. Page 682 Fuseblock (Part 1 Of 2) Page 673 Transmission Overdrive System (Part 1 Of 3) Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch from mounting bracket, then disconnect switch from wiring harness. 2. Using a suitable ohmmeter, ensure switch continuity is as follows: a. With switch plunger released, continuity should exist between pins 5 and 6. b. With switch plunger depressed, continuity should exist between pins 1 and 2 and between pins 3 and 4. 3. If switch continuity is as specified, switch is satisfactory; if not, replace switch. Adjustments Air/Fuel Mixture: Adjustments CAUTION: Some models are equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle mixture using this screw! Idle mixture is electronically controlled by the Powertrain Control Module (PCM), and is not adjustable. If an idle mixture problem is suspected, check oxygen sensor and feedback system. SEE Computers and Control Systems. Rear Differential - Trac-Loc Chatter Fluid - Differential: All Technical Service Bulletins Rear Differential - Trac-Loc Chatter NO: 03-03-95 GROUP: Rear Axle DATE: May 5, 1995 SUBJECT: Rear Axle Trac-Loc Chatter THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-94 DATED JULY 8, 1994 WHICH SHOULD BE NOTED IN THE 1994 TSB BOUND BOOK (PUBLICATION NO. 81-699-95054). ALL REVISIONS ARE MARKED WITH **ASTERISKS**. THE 1995 MODEL YEAR HAS BEEN ADDED, AS WELL THE TRAC-LOC ADDITIVE NOW COMES IN 4 OUNCE CONTAINERS. MODELS: 1994 - **1995** (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO 8800 GVW,** 7500 GVW, 10500 GVW, 11000 GVW VEHICLES EQUIPPED WITH TRAC-LOK AND DANA MODEL 60, 70 & 80 AXLES.** SYMPTOM/CONDITION: Rear axle Trac-Loc chatter while turning corners. DIAGNOSIS: Road test the vehicle. If the noise is present, perform the repair procedure. PARTS REQUIRED: 4 4796517 Gear Oil **2 4318060 Trac-Lok Additive (4 oz.)** NOTE: IT IS IMPORTANT THAT ONLY THE GEAR OIL SPECIFIED ABOVE BE USED. IF IMPROPER OIL IS USED, INSUFFICIENT LUBRICATION RESULTS. REPAIR PROCEDURE: This bulletin involves draining and refilling the rear axle with a new fluid and adding Trac-Lok additive. 1. Operate the vehicle to ensure that the rear axle is warm. 2. Remove the rear axle cover and drain all of the fluid from the housing and wipe as much fluid out of the housing as possible. 3. Install the cover using Mopar RTV, P/N 82300234, to seal. 4. Add two bottles of additive, P/N 4318060. 5. Fill the axle with gear oil, P/N 4796517, per the Ram Truck Service Manual (Publication No. 81-370-5108), and install the fill plug. 6. Drive the vehicle at least 10 miles. Make eight figure 8 turns and three 90 degree turns, stopping for 10 seconds between each turn. This procedure will work the new fluid and additive into the Trac-Lok unit. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 03-00-02-91 1.0 Hrs. FAILURE CODE: 68 - Noisy Page 16 Related Images Page 592 Schematic Diagrams Upper Radiator Hose - Premature Wear Radiator Hose: Technical Service Bulletins Upper Radiator Hose - Premature Wear NO: 07-01-95 GROUP: Cooling DATE: May 5, 1995 SUBJECT: BR Upper Radiator Hose Wear MODELS: 1994 - 1995 (BR) Ram Truck NOTE: THIS BULLETIN APPLIES TO All RAM TRUCKS EQUIPPED WITH AN 8.OL (V-10) BUILT PRIOR TO MAY 1,1995 (MDH 05-01-XX). SYMPTOM/CONDITION: Premature wear of the upper radiator hose may exist due to contact with the A/C manifold. PARTS REQUIRED: 1 52028641 Upper Radiator Hose with Protective Sleeve 1 52028568 Manifold Cap, A/C Compressor REPAIR PROCEDURE: This bulletin involves replacement of the upper radiator hose with a protective sleeve, and installing a protective cap on the A/C compressor manifold. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. 1. Drain the cooling system. If fluid is clean, save for reuse when refilling. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 ( FIGURE 1). SNAP-ON CLAMP TOOL NUMBER HPC-20 MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. A NUMBER OR LETTER IS STAMPED INTO THE TONGUE OF CONSTANT TENSION CLAMPS. IF REPLACEMENT IS NECESSARY, USE ONLY AN ORIGINAL EQUIPMENT CLAMP WITH A MATCHING NUMBER OR LETTER. 2. Remove hose clamps and upper radiator hose. 3. Install the new style radiator hose. Ensure clamps are in the proper location and secure. Page 727 Fig.4 Roof Wiring Page 442 Cigar Lighter And Glove Box Lamp Page 310 3. Install the switch knob and shaft on the new switch assembly by depressing the release button on the bottom of the switch assembly and then inserting the shaft into the switch assembly. Fig. 10 4. Connect the 9-way wiring connector to the headlamp switch. Fig. 10 5. Connect the 2-way wiring connector to the headlamp switch (if equipped). Fig. 10 Page 598 Anti-Lock Brake System (Part 4 Of 4) Page 509 Anti-Lock Brake System (Part 2 Of 4) Page 409 Engine Connector-C Page 611 Front End Lighting With Daytime Running Lamps (Part 1 Of 2) Page 309 Fig. 9 8. Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness. Fig. 8 9. Insert the two wire terminals from the overlay harness into the headlamp switch connector. Insert the PINK wIRED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity. 10. Secure the wire terminals in the headlamp switch connector with the provided 9-way wedge. C. Install the Headlamp Switch Assembly: 1. Install the headlamp switch bezel bracket on the new switch assembly. 2. Install the headlamp switch bezel on the mounting bracket. Tighten the three (3) mounting screws securely. Fig. 10 Page 652 Fuel Tank System Complete System Diagram For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management Fuel Pump For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams System Diagram For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Ignition Control Module For information regarding diagrams for this system, please refer to Powertrain Management diagrams. See: Powertrain Management/Diagrams/Electrical Diagrams Page 522 Headlamp Switch And Joint Connector(A) Wiring (Part 1 Of 2) Page 42 Compressor Clutch Relay: Service and Repair Fig 24 Power Distribution Center 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. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable(s). 8. Test the relay operation. Electrical Specifications Engine Coolant, Intake Air, And Transmission Temperature Sensor Specifications Page 878 Throttle Position Sensor: Adjustments PROCEDURE ^ The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. ^ If sensor output voltage is outside acceptable range, sensor should be replaced. Page 946 Impact Sensor: Service and Repair Right Impact Sensor 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the three screws that secure the impact sensor to the front wheelhouse extension. 3. Unplug the wire harness connector from the impact sensor and remove the sensor. NOTE: Do not remove the tape that secures the sensor wiring harness to the connector. 4. To install, plug in the sensor wire harness connector to the impact sensor. 5. Mount the sensor (arrow pointed forward) using the three screws provided with the new sensor. Tighten the screws to 5 to 6 N.m (45 to 55 in. lbs.). 6. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Page 581 Body Connector Page 271 5. Remove the terminal from cavity # 2 (See Figure 1). 6. Insert the terminal from the harness, P/N 4773164, into cavity # 2. 7. Install the wedge into the connector. 8. Install the connector to the sending unit. 9. Tie strap the harness along the chassis to the original harness following it into the engine compartment. 10. Drill a 1/2" hole in the dash panel as shown in Figure 2. 11. Route the harness through the hole and seat the grommet. 12. Remove the knee blocker, the IP cluster and disconnect the cluster connectors. 13. Route the harness through the dash to the cluster area. 14. Remove the wedge from the cluster connector (See Figure 3) being careful not to break it. 15. Remove the terminal from cavity F (AN Body) or A (AD Body). (See Figure 3). Air Bag Control Module 4 Way Connector Air Bag Control Module Connector Page 594 Rear Wheel ABS System (Part 2 Of 2) Page 131 International Symbol Identification Chart Wire Color Codes Black: BK Blue: BL Brown: BR Dark Blue: DB Dark Green: DG Gray: GY Light Blue: LB Light Green: LG Orange: OR Pink: PK Red: RD Tan: TN Violet: VT White: WT Yellow: YL Page 410 Warning Lamp Relay Related Images Page 515 Fender And Tailgate Lamps (Dual Rear Wheels) Page 873 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 354 Fig. 9 8. Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness. Fig. 8 9. Insert the two wire terminals from the overlay harness into the headlamp switch connector. Insert the PINK wIRED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity. 10. Secure the wire terminals in the headlamp switch connector with the provided 9-way wedge. C. Install the Headlamp Switch Assembly: 1. Install the headlamp switch bezel bracket on the new switch assembly. 2. Install the headlamp switch bezel on the mounting bracket. Tighten the three (3) mounting screws securely. Fig. 10 Page 32 Blower Motor Relay: Description and Operation Fig 39 Blower Motor Relay Removal/Installation Blower Motor Relay 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 fuse block module to the blower motor, whenever the ignition switch is in the On position. This arrangement reduces the amount of battery current that must flow through the ignition switch. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. When the relay is de-energized, the blower motor receives no battery feed. The relay is located in the passenger compartment on the stop lamp switch bracket. The stop lamp switch bracket is secured to the inboard side of the pedal support bracket under the driver side of the instrument panel. The relay case includes a molded-in plastic slot that snaps over the blade-type relay mount on the stop lamp switch bracket. The relay cannot be repaired and, if faulty or damaged, it must be replaced. CIRCUIT OPERATION Circuit C1 from fuse 2 in the Fuse Block supplies voltage to the contact side of the blower motor relay When the ignition switch is in the RUN position it connects Circuit A2 from fuse 2 in the Power Distribution Center (PDC) to Circuit A22. Circuit A22 connects to the coil side of the blower motor relay Circuit C1 connects to Circuit C11 through the blower motor relay contacts and supplies voltage to the blower motor. Circuit Z3 provides the ground path for the blower motor relay. Specifications Throttle Position Sensor: Specifications Mounting Bolt Torque .......................................................................................................................... .................................................... 7 Nm (60 in. lb.) Page 352 Fig. 7 ^ Carefully inspect the connector and terminals B1, B2, R and H for signs of damage from overheating (melted connector and/or discolored terminal). If any one of these terminals shows signs of damage, ALL FOUR of these terminals MUST be replaced. Continue with Step 3. ^ Carefully inspect the connector and all other terminals. If any terminals in addition to B1, B2, R and H are damaged, terminals B1, B2, R, H and any other damaged terminals MUST be replaced. Continue with Step 3. ^ If there is no indication of heat damage, continue with Step 6. 3. For vehicles with headlamp switch wire terminal and connector heat damage: Remove any damaged wire terminals from the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent. If the connector is also damaged and cannot be reused, remove all wires and discard the connector. 4. Replace any damaged wires as determined in Step 2 as follows: a. Cut the electrical tape and remove the affected wire(s) from the bundle. b. Cut off the damaged wire approximately 10 inches from the terminal. NOTE: Stagger the wire splice locations by about 1/2 inch. c. Remove about 1 inch of insulation from the end of the wire. d. Remove about l inch of insulation from the end of the matching color and gauge wire and terminal provided in the parts package. e. Slip one piece of the provided heat shrink tubing over the new wire end. f. Twist the exposed wire ends of the harness wire and the replacement wire end together. g. Solder the twisted wire ends together using rosin core solder. CAUTION: All wiring splices must be soldered or future circuit failure may occur. h. Slide the heat shrink tubing over the wire splice and heat the tubing until the tubing shrinks tightly around the wire and sealant comes out both ends of the tubing. i. Repeat Steps A - H for all other damaged wires as necessary. Component Locations Powertrain Control Module: Component Locations PCM Location The Powertrain Control Module (PCM) is located on the firewall at the right-hand rear corner of the engine compartment. Page 926 Page 587 Power Distribution Center Page 1149 Drive Belt: Diagrams Fig. 40 Serpentine Drive Belt Routing Fig. 40 Serpentine Drive Belt Routing Page 335 Fig. 8 5. Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R". Retape the wiring bundle as necessary. Fig. 8 6. For vehicles WITHOUT headlamp switch connector or terminal heat damage: Remove the PINK w/RED TRACER wire from location "B2" and the BLACK w/YELLOW TRACER wire from location "R" of the headlamp switch connector using a small screwdriver, Miller Special Tool # 8197 or equivalent. Fig. 9 7. Insert the wire terminals that were originally in locations "B2" and "R" of the headlamp wiring connector into the supplied 2-way wiring connector. Insert the PINK wired TRACER wire into the (+) cavity. Insert the BLACK w/YELLOW TRACER wire into the (-) cavity. Secure the terminals with the provided 2-way wedge. Page 644 Fuel Injection Ignition System (Part 5 Of 10) Page 400 Vehicle wiring harnesses are equipped with fusible links to protect against harness damage in the event of a short in the system. Fusible links are color coded to indicate wire gauge and size. Refer to the fusible link chart for color and gauge identification. Wire Gauge Color Code Wire Color 12 Ga BK Black 14 Ga RD Red 16 Ga DB Dark Blue 18 Ga GY Gray 20 Ga OR Orange 22 Ga WT White Main Circuit ID Codes Main Circuit Identification 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. Page 545 Air Conditioning And Heater System (Part 1 Of 2)